Processes and/or machines for producing continuous plastic deformation, and/or compositions and/or manufactures produced thereby

ABSTRACT

Certain exemplary embodiments can provide a manufacturing method, process, machine, and/or system for continuously consolidating granular materials, creating new alloys and/or composites, and/or modifying and/or refining material microstructure, by using plastic deformation of feedstock(s) provided in various structural forms. Materials produced during this process can be fabricated directly and/or in forms such as, e.g., wires, rods, tubes, sheets, plate and/or channels, etc.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims priority to, and incorporates by referenceherein in its entirety, pending U.S. Provisional Patent Application63/156,497, filed 4 Mar. 2021.

BRIEF DESCRIPTION OF THE DRAWINGS

A wide variety of potential, feasible, and/or useful embodiments will bemore readily understood through the herein-provided, non-limiting,non-exhaustive description of certain exemplary embodiments, withreference to the accompanying exemplary drawings in which:

FIG. 1 is a perspective view of an exemplary embodiment of a machine1000;

FIG. 2 is a side view of an exemplary embodiment of a machine 1000;

FIG. 3 is a bottom view of an exemplary embodiment of a machine 1000;

FIG. 4 is a top view of an exemplary embodiment of a machine 1000;

FIG. 5 is a cross-sectional view, taken at section A-A of FIG. 4 , of anexemplary embodiment of a machine 1000;

FIG. 6 is a side view of an exemplary embodiment of a machine 1000;

FIG. 7 is a perspective view of an exemplary embodiment of a machine1000;

FIG. 8 is a cross-sectional view, taken at section S-S of FIG. 12 , ofan exemplary embodiment of a machine 1000;

FIG. 9 is a cross-sectional view, taken at section S-S of FIG. 12 , ofan exemplary embodiment of a machine 1000;

FIG. 10 is a cross-sectional view, taken at section S-S of FIG. 12 , ofan exemplary embodiment of a machine 1000;

FIG. 11 is a cross-sectional view, taken at section S-S of FIG. 12 , ofan exemplary embodiment of a machine 1000;

FIG. 12 is a side view of an exemplary embodiment of a machine 1000;

FIG. 13 is a cross-sectional view, taken at section S-S of FIG. 12 , ofan exemplary embodiment of a machine 1000;

FIG. 14 is a cross-sectional view, taken at section S-S of FIG. 12 , ofan exemplary embodiment of a machine 1000;

FIG. 15 is a cross-sectional view, taken at section S-S of FIG. 12 , ofan exemplary embodiment of a machine 1000;

FIG. 16 is a cross-sectional view, taken at section S-S of FIG. 12 , ofan exemplary embodiment of a machine 1000;

FIG. 17 is a cross-sectional view, taken at detail D of FIG. 16 , of anexemplary embodiment of a machine 1000;

FIG. 18 is a cross-sectional view, taken at detail D of FIG. 16 , of anexemplary embodiment of a machine 1000;

FIG. 19 is a cross-sectional view, taken at detail D of FIG. 16 , of anexemplary embodiment of a machine 1000;

FIG. 20 is a side view of an exemplary embodiment of a machine 1000;

FIG. 21 is a cross-sectional view, taken at section A-A of FIG. 20 , ofan exemplary embodiment of a machine 1000;

FIG. 22 is a cross-sectional view, taken at section S-S of FIG. 12 of anexemplary embodiment of a machine 1000;

FIG. 23 is a cross-sectional view, taken at section S-S of FIG. 12 , ofan exemplary embodiment of a machine 1000;

FIG. 24 is a cross-sectional view, taken at section S-S of FIG. 12 , ofan exemplary embodiment of a machine 1000;

FIG. 25 is a cross-sectional view, taken at section S-S of FIG. 12 , ofan exemplary embodiment of a machine 1000;

FIG. 26 is a cross-sectional view, taken at section S-S of FIG. 12 , ofan exemplary embodiment of a machine 1000;

FIG. 27 is a cross-sectional view, taken at section S-S of FIG. 12 , ofan exemplary embodiment of a machine 1000;

FIG. 28 is a cross-sectional view, taken at section S-S of FIG. 12 , ofan exemplary embodiment of a machine 1000;

FIG. 29 is a cross-sectional view, taken at section S-S of FIG. 12 , ofan exemplary embodiment of a machine 1000;

FIG. 30 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 31 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 32 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 33 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 34 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 35 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 36 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 37 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 38 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 39 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 40 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 41 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 42 is a side view of an exemplary embodiment of a rotor 1200;

FIG. 43 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 44 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 45 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 46 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 47 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 48 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 49 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 50 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 51 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 52 is a side view of an exemplary embodiment of a rotor 1200;

FIG. 53 is a bottom view of an exemplary embodiment of a rotor 1200;

FIG. 54 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 55 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 56 is a side view of an exemplary embodiment of a rotor 1200;

FIG. 57 is a bottom view of an exemplary embodiment of a rotor 1200;

FIG. 58 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 59 is a side view of an exemplary embodiment of a rotor 1200;

FIG. 60 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 61 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 62 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 63 is a perspective view of an exemplary embodiment of a rotor1200;

FIG. 64 is a perspective view of an exemplary embodiment of a container1400;

FIG. 65 is a side view of an exemplary embodiment of a container 1400;

FIG. 66 is a cross-sectional view, taken at section B-B of FIG. 65 , ofan exemplary embodiment of a container 1400;

FIG. 67 is a perspective view of an exemplary embodiment of a container1400;

FIG. 68 is a side view of an exemplary embodiment of a container 1400;

FIG. 69 is a cross-sectional view, taken at section B-B of FIG. 68 , ofan exemplary embodiment of a container 1400;

FIG. 70 is a perspective view of an exemplary embodiment of a container1400;

FIG. 71 is a side view of an exemplary embodiment of a container 1400;

FIG. 72 is a cross-sectional view, taken at section B-B of FIG. 71 , ofan exemplary embodiment of a container 1400;

FIG. 73 is a perspective view of an exemplary embodiment of a container1400;

FIG. 74 is a side view of an exemplary embodiment of a container 1400;

FIG. 75 is a cross-sectional view, taken at section B-B of FIG. 74 , ofan exemplary embodiment of a container 1400;

FIG. 76 is a perspective view of an exemplary embodiment of a container1400;

FIG. 77 is a side view of an exemplary embodiment of a container 1400;

FIG. 78 is a cross-sectional view, taken at section B-B of FIG. 77 , ofan exemplary embodiment of a container 1400;

FIG. 79 is a perspective view of an exemplary embodiment of a container1400;

FIG. 80 is a side view of an exemplary embodiment of a container 1400;

FIG. 81 is a cross-sectional view, taken at section B-B of FIG. 80 , ofan exemplary embodiment of a container 1400;

FIG. 82 is a perspective view of an exemplary embodiment of a container1400;

FIG. 83 is a side view of an exemplary embodiment of a container 1400;

FIG. 84 is a cross-sectional view, taken at section B-B of FIG. 83 , ofan exemplary embodiment of a container 1400;

FIG. 85 is a block flow diagram of an exemplary embodiment of a process10000;

FIG. 86 is a cross-sectional view, taken at section S-S of FIG. 12 , ofan exemplary embodiment of a machine 1000;

FIG. 87 is a detailed view of FIG. 86 , of an exemplary embodiment of amachine 1000;

FIG. 88 is a side view of an exemplary embodiment of a machine 1000;

FIG. 89 is a cross-sectional view, taken at section A-A of FIG. 88 , ofan exemplary embodiment of a machine 1000;

FIG. 90 is a detailed view of an identified portion of FIG. 89 ;

FIG. 91 is a perspective view of an exemplary embodiment of a machine1000;

FIG. 92 is a top view of an exemplary embodiment of a machine 1000;

FIG. 93 is a cross-sectional view, taken at section A-A of FIG. 92 , ofan exemplary embodiment of a machine 1000;

FIG. 94 is a top view of an exemplary embodiment of a machine 1000,showing a rotational position of rotor 1200 at a first time;

FIG. 95 is a top view of an exemplary embodiment of the machine 1000 ofFIG. 94 , but showing a rotational position of rotor 1200 at a secondtime;

FIG. 96 is a cross-sectional view, taken at section A-A of FIG. 94 , ofan exemplary embodiment of machine 1000;

FIG. 97 is a front view of an exemplary embodiment of a machine 1000;

FIG. 98 is a side view of an exemplary embodiment of a machine 1000;

FIG. 99 is a cross-sectional view, taken at section A-A of FIG. 97 , ofan exemplary embodiment of machine 1000;

FIG. 100 is a detailed view of an identified portion of FIG. 99 ;

FIG. 101 is a cross-sectional view, taken at section B-B of FIG. 98 , ofan exemplary embodiment of machine 1000;

FIG. 102 is a detailed view of an identified portion of FIG. 101 ;

FIG. 103 is a side view of an exemplary embodiment of a rotor 1200;

FIG. 104 is a side view of an exemplary embodiment of a rotor 1200;

FIG. 105 is a distal end view of an exemplary embodiment the rotor 1200of FIG. 103 and/or FIG. 104 ; and

The following table links each numbered drawing element to itsdescription:

1000 Machine 1120 Feeder A 1121 Feedport entrance A 1122 Feedstock A1123 Feed mechanism A 1124 Feedport A 1126 Feedport exit A 1140 Feeder B1141 Feedport entrance B 1142 Feedstock B 1143 Feed mechanism B 1144Feedport B 1146 Feedport exit B 1150 Filling 1160 Feeder drive 1200Rotor 1210 Non-Contact portion 1220 Contact portion 1240 Semi-Containedportion 1260 Contained portion 1280 Distal end portion 1285 Distalterminus 1286 Distal visible perimeter 1288 Proximal visible perimeter1289 Annular portion 1290 Conduit 1295 Rotor passage 1298 Rotorprotrusion 1300 Drive 1400 Container 1410 Container body 1420 Containerinner surface 1440 Container housing 1460 Container layer 1480 Containerexit 1498 Container protrusion 1500 Die 1520 Die plate 1620 Substrate1640 Bed 1660 Frame 1670 Feeder frame 1680 Deposited material 1700Stirred material 1800 Extruded material 1850 Extruded tube 1900 Cavity

DESCRIPTION

Referring to FIGS. 1-105 , certain exemplary embodiments can provide amethod, process, device, machine, and/or system for continuouslyconsolidating granular materials, creating new alloys and/or composites,and/or modifying and/or refining material microstructure, by usingplastic deformation of feedstock(s) provided in various structuralforms. Materials produced in this manner can be fabricated directly andin forms such as, e.g., wires, rods, tubes, sheets, plate and/orchannels, etc., and/or deposited directly on a substrate to create athree-dimensional structure. Certain exemplary embodiments can operateindependently and/or can be augmented with equipment having at least onerotating spindle and/or rotor such as a friction stir welding machine,lathe, milling machine, and/or drilling machine, etc.

FIGS. 1-6 show an exemplary embodiment of a machine 1000, whichcomprises feeders 1120, 1140 that are configured to feed at least onefeedstock toward a non-rotating and/or stationary container 1400 thatdefines an interior cavity 1900. A rotor 1200, which can be located atleast partially within cavity 1900, can rotate around a rotational axisR-R, with/without translation along rotational axis R-R, to causecontinuous, severe, and/or plastic deformation of at least one feedstockwithin a cavity 1900 defined in container 1400. Feeders 1120, 1140,container 1200, and/or rotor 1400 can be supported by a bed 1640 and/ora frame 1660. Feeders 1120, 1140 can be driven by a drive and/oractuator 1160.

As shown in FIGS. 7-11 , a feedstock 1122, 1142 that includes at leastone malleable and/or deformable material in non-liquid form can be fedinto cavity 1900 while rotor 1200 is rotating and/or translating duepower applied by drive 1300. Note that for clarity FIGS. 7-11 do notshow cross hatching.

FIG. 12 represents a generic rotor 1200 and container 1400, which arepresented to show cross-sectional plane S-S that defines the view ofFIGS. 13-19 , among others. Note that to clarify and highlightfeedstocks 1122, 1142, stirred material 1700, and extruded material1800, FIGS. 17-19 do not show cross hatching for rotor 1200 or container1400. Upon entering cavity 1900, feedstock 1122, 1142 can touch movingrotor 1200 and/or become transformed into stirred material 1700. Thestirred material 1700 itself, entering feedstock 1122, 1142, and/or oneor more wipers that can be operable using external actuators (which, asseen in FIGS. 94, 95, and 96 , can be a rotor protrusion 1298 that isattached to or integral to rotor 1200 and/or a container protrusion 1498that is attached to or integral to container 1400) that protrude intocavity 1900, any such wiper less deformable than and/or non-deformablewith respect to at least one of the feedstocks at the temperatures andpressures present in cavity 1900, can fully or partially wipe,dislocate, and/or urge stirred material 1700, which is then in contactwith rotor 1200, off of and/or along rotor 1200. Wiping can help reducebuild-up of stirred material 1700 on rotor 1200 that might otherwisecause little to no stirred material to advance toward die 1500. Wipingof stirred material 1700 from and/or along rotor 1200 can transferforces applied to push feedstock 1122, 1142 toward cavity 1900 ontostirred material 1700, which can help advanced stirred material 1700towards non-rotating and/or stationary die 1500, and/or can allowentering feedstock 1122, 1142 and/or stirred material 1700 to moreeasily and/or rapidly undergo plastic deformation, consolidation,distribution, and/or microstructure modification. The degree of wipingcan range from approximately 1% to approximately 99% of the stirredmaterial then in the cavity per rotor revolution.

Referring to FIGS. 17-19 , within cavity 1900 heat can be generated dueto frictional contact between a feedstock 1122 and the interior walls ofcontainer 1400, the rotating and/or translating rotor 1200, and/or otherfeedstock, and/or due to deformation of the feedstock. Such heat canfurther soften and/or deform the feedstock within cavity 1900. Feedstock1122 that enters cavity 1900 while rotor 1200 is moving is consideredstirred material 1700. Due to the motion of rotor 1200, stirred material1700 can flow towards non-rotating and/or stationary die 1500 and/or acontainer exit and/or be pushed through die 1500 and/or a containerexit, eventually emerging from container 1400 as extruded material 1800.Generally, FIGS. 17-19 show the flow direction of stirred material 1700.This flow can be linear, turbulent, and/or chaotic.

Within cavity 1900, a through mixing of feedstock can be achieved. Ifdissimilar feedstock and/or filler materials and/or reinforcement phasesare fed into cavity 1900, the harder phases can be uniformly distributedwithin the softer matrix materials. The deformation, level of mixing,stirred material temperature, and/or processing time can be controlledto allow for in-situ composite manufacturing and/or in-situ solid-statealloying. The deformation achieved in stirred material 1700 can be afunction of rotational speed, rotor geometry, container geometry, feedstock geometry, and/or feedstock feeding rate. Increases in rotationalspeed and/or diameter and/or length of rotor 1200 can increase thedeformation.

As shown in FIG. 19 , during normal operation of the machine, a radialgap GR and/or an axial gap GA can exist between rotor 1200 and container1400 and the magnitude of each such gap can change over time as rotor1200 rotates and/or translates. For example, within the cross-sectionshown in FIG. 19 , which contains rotational axis R-R, a magnitude ofaxial gap GA can be defined as a distance measured along a line segmentthat extends parallel to rotational axis R-R and between a centroid CF(and/or along a line segment that extends parallel to rotational axisR-R and from a radial line that is oriented perpendicular to rotationalaxis R-R and that intersects centroid CF) of a feedstock exit 1126, 1146and the then-closest point to centroid CF, that closest point located onthe exterior surface of the contained portion 1260 of rotor 1200.Likewise, on the same cross-section, a magnitude of radial gap GR can bedefined as a distance measured along a line segment that extendsperpendicular to the rotational axis and between centroid CF and thethen-closest point to centroid CF that's located on the exterior surfaceof the contained portion 1260 of rotor 1200. Stated differently, amagnitude of the axial gap can continuously change across time, theaxial gap being measured along a first line extending in a predeterminedperpetual cross-sectional plane that includes the rotational axis, thefirst line extending parallel to the rotational axis, the gap being theshortest distance, on the predetermined perpetual cross-sectional planeand along the first line, between (a) the exterior surface of the rotorand (b) a second line that extends in the predetermined perpetualcross-sectional plane, is perpendicular to the rotational axis, andintersects a centroid of an exit of the first feedport. A magnitude ofthe radial gap can continuously change across time, the radial gapmeasured being along the second line and being the shortest distance, onthe predetermined perpetual cross-sectional plane and along the secondline, between the exterior of the rotor and the first line. Stated inyet another manner, the axial distance and/or radial distance betweenthe feedport centroid and the rotor can change over time.

Depending on the dimensions of rotor 1200 and/or container 1400, viewedon a cross-section that is perpetual and/or unchanging over time in itsorientation, such as that of FIG. 19 , a magnitude of radial gap GRand/or axial gap GA can change over time. The magnitude of radial gap GRcan change, potentially within a single rotation of rotor 1200 to within100 rotations of rotor 1200, from zero (i.e., direct contact betweenrotor 1200 and container 1400) to (assuming rotor 1200 is withdrawnsufficiently from cavity 1900) a distance equal to maximum radius ofcontainer 1400 for a radius that is measured perpendicularly torotational axis R-R and passes through the centroid CF. The magnitude ofaxial gap GA can change, potentially within a single rotation of rotor1200 to within 10,000 rotations of rotor 1200, from zero (i.e., directcontact between rotor 1200 and container 1400) to (assuming rotor 1200is withdrawn sufficiently from cavity 1900) a distance equal to thedistance from the proximal entrance of rotor 1200 into container 1400and centroid CF as measured along a line that passes through centroid CFand is parallel to rotational axis R-R. of the contained portion 1260 ofrotor 1200 during the time needed for one revolution of the containedportion 1260 of rotor 1200 within cavity 1900. The change in themagnitude of axial gap GA can be limited by the maximum travel distance,along a line extending parallel to the axis of rotation, of contactportion 1220 away from container inner surface 1420 and/or contact ofthe exterior surface of contained portion 1260 with container innersurface 1420. The change in the magnitude of radial gap GR can belimited by the maximum possible distance, measured along a lineextending perpendicular to the axis of rotation, of contained portion1260 from container inner surface 1420 within cavity 1900 and/or contactof the exterior surface of contained portion 1260 with container innersurface 1420. The magnitude of any gap, including radial gap GR and/oraxial gap GA, can be measured using any traditional gap measurementdevice, including a ruler, feeler gauge, caliper, micrometer, gapsensor, gap monitor, optical or imaging gap gauge, laser scanner,capacitance gap sensor, eddy current gap sensor, air or pneumatic gapsensor, industrial computed tomography (ICT), and/or X-ray radiography,etc.

Decreases in a magnitude of radial gap GR, axial gap GA, and/or the dieexit cross-sectional area can increase the deformation of stirredmaterial 1700. The deformation can be measured in terms of strain and/orstrain rate. Strain can vary between approximately 0.1 and approximately200, and/or strain rate can vary between 0.1/s and 1000/s, at locationscloser to the contact between rotor 1200 and stirred material 1700.Strain can be measured by comparing the dimensional and/or orientationchange of a feedstock from various locations and/or by comparing anaverage aspect ratio of a feedstock's grains prior to and postdeformation and/or by comparing measurements of surface markings such asa grid pattern and/or marker material that has been placed on anexterior surface of the feedstock, where any dimensional and/ororientation measurement is performed using well-known measurementtechniques. Likewise, strain can be measured according to standards suchas ASTM D790 and/or ASTM E1319-21.

The reduction in cross-sectional area at the initial contact betweenfeedstock 1122, 1142 and rotor 1200 can be measured by calculating theratio between the changed cross-sectional area and the originalcross-sectional area of feedstock 1122, 1142. The change incross-sectional area is the difference in cross-sectional area betweenthe original cross-sectional area of the feedstock and thecross-sectional area of the feedstock entering cavity 1900. Thefeedstock thickness entering cavity 1900 can be measured by measuringthe gap between rotor 1200 and container 1400. The percentage reductionin cross-sectional area for a full-size solid feedstock at a feedport1124, 1144 can be calculated from the following formula:

${\%{reduction}{in}{area}} = {\frac{{CS}_{feedstock} - \left( {h_{feedstock} \times t_{{def}.{layer}}} \right)}{{CS}_{feedstock}} \times 100}$

-   -   where, CS_(feedstock) is cross-sectional area of the feedport;        h_(feedstock) is height of the feedport, and t_(def.layer) is        thickness of deformed layer, which is equal to the magnitude        (e.g., thickness) of the gap between container 1400 and rotor        1200.

The percentage reduction in cross-sectional area at the feedstock entrycan vary from approximately 1% to approximately 99%. The initialreduction in cross-sectional area can further be reduced during downwardmovement of the stirred material. The final change in cross-sectionalarea can be calculated by using the following formula.

${\%{Change}{in}{cross}{section}{area}} = {\frac{{CS}_{feedstock} - {CS}_{{extruded}{material}}}{{CS}_{feedstock}} \times 100}$

-   -   where, CS_(feedstock) is the cross-sectional area of the        feedport and CS_(extruded material) is the cross-sectional area        of the extruded material.

Since certain exemplary embodiments can be used to consolidate variousfeedstock materials, the final cross-sectional area can be higher thanthe initial feedstock's cross-sectional area. In this case, thereduction in cross-sectional area can be negative based on the aboveformula for calculating the percentage reduction in cross-sectionalarea.

The level of mixing in cavity 1900 can be increased by increasing therotational speed and/or by providing rotor features and/or containerfeatures that promote localized material flow before the processedmaterial exits die 1500. In various exemplary embodiments, the level ofmixing can be inferred and/or determined by studying the microstructure(e.g., size, shape, type, and/or density of crystals, grains, phases,secondary particles, reinforcement particles, dispersoids, dislocations,and/or voids, etc.) of the extruded material 1800 for uniformity. Forexample, a substantially uniform distribution of reinforcement particlesand/or a uniform distribution of secondary phases might meansatisfactory mixing and/or might distinguish an extruded material 1800formed from machine 1000 from materials created and/or processed viaother machines, tools, and/or processes. A non-uniform microstructureand/or non-distribution and/or agglomeration of alloying elements,phases, secondary phases, and/or reinforcement phases might indicateinsufficient mixing. A microstructure can be considered sufficientlymodified when, with respect to the microstructure of the feedstock, themicrostructure of the extruded material exhibits a difference:

a. in average grain size change of 5% or more as measured using ASTM E112-13, ASTM E2627-13, and/or ASTM E1382-97(2015);

b. in average dislocation density change of 5% or more as counted onelectron microscopic images, and/or

-   -   c. in change of distribution, shape, size, and/or number of        secondary phases of 5% or more as determined using ASTM        E1245-03.

The temperature of rotor 1200, container 1400, and/or extruded material1800 can be measured using various methods such as one or morethermocouples, infra-red thermal cameras, etc. The temperature offeedstock 1122, 1142, the stirred material 1700, and/or the extrudedmaterial 1800 at any time and/or location during the operation can be upto approximately 0.95 times the melting point of the feedstock 1122,1142. For example, when processing aluminum, the temperature of stirredmaterial 1700 can reach as high as 627 C. When processing dissimilarfeedstocks 1122, 1142, the temperature of the stirred material 1700 canreach approximately 0.95 times of the melting point of a feedstockhaving the highest melting point. In this case, the temperaturegenerated in one feedstock can cause the onset of incipient melting. Atleast one feedstock being processed can remain in a solid state.

Via certain exemplary embodiments, at least one of the feedstocks 1122,1142 can be plastically deformed by rotor 1200 almost immediately afterentering container 1400 and/or cavity 1900. The plasticized feedstockmaterial/stirred material 1700 can be moved around cavity 1900 by rotor1200, which can force that stirred material 1700 downward with the aidof pressure difference generated by rotor 1200 and/or the feed pressure.The material flow and/or pressure caused by rotor 1200 and/or the feedpressure can be utilized for extrusion. The extruded material 1800 canflow from machine 1000 substantially continuously and/or uniformlyacross time and/or its cross-sectional area with respect to itsproperties such as composition, density, shape, microstructure, etc.

Rotor 1200 can range between approximately 1 mm and approximately 500 mmin diameter at the non-contact portion 1210 and/or contact portion 1220and/or between approximately 1 mm and approximately 1000 mm in length.Generally, smaller diameter rotors can operate at a higher rotationspeed, and/or larger diameter rotors can have higher torquerequirements. The selection of the size and/or material of rotor 1200can depend on the feedstock material or materials and/or its/theirgeometry. The friction force can be calculated by multiplying thecontact area of rotor 1200 with the flow stress of the feedstock at thetime of contact and the corresponding coefficient of friction. Forexample, when processing a feedstock with a 20 MPa flow stress at aprocessing temperature using a rotor 1200 with 100 mm² surface area andcoefficient of friction 0.5, the frictional forces will be approximately1000 N. If a rotor 1200 had 5 mm diameter the torque requirement wouldbe 5 Nm. Similarly, depending on the size of rotor 1200 and/or thestirred material 1700, the friction force can range from approximately0.1 kN to approximately 5000 kN. For processing feedstocks with asurface area of less than approximately 100 mm², the torque requirementoften can be satisfied by an approximately 1 HP electrical motor, whichcan be available in conventional industrial machine tools such asmilling machines, lathe, drilling machines etc. Certain exemplaryembodiments of machine 1000 can be implemented on commonly availablemachine tools having rotary spindles, such as milling machines, lathes,drilling machines, etc. In this case, rotor 1200 can be attached to therotary spindle. An independent, standalone machine 1000 can have its ownspindle with a drive system. Hence, certain exemplary embodiments ofmachine 1000 can operate independently and/or can inter-operate with amachine such as, but not limited to, a friction stir welding machine,drilling machine, lathe, and/or milling machine, etc.

Since rotor 1200 can be completely moved and/or translated out of cavity1900 at the end of the process and/or at any point during the processwhile rotor 1200 is rotating, the potential problem of rotor 1200sticking and/or bonding to container 1400 can be reduced and/or avoidedand/or rotor 1200 easily can be cleaned and/or wiped.

To avoid excessive wear of rotor 1200 and/or container 1400 due to acontinuous exposure to high temperature and/or contact forces, theprocess can be carried out by applying an intermittent cooling cycle torotor 1200 and/or container 1400, which can allow feedstocks 1122, 1142with high flow stresses and/or high plastic deformation temperatures,such as ferrous alloys, nickel alloys, cobalt alloys, etc., to beprocessed. Depending on the feedstocks being processed, additionalheating and/or cooling can be provided to container 1400 and or to rotor1200 via external means.

More than one feedstock type and/or form such as, but not limited to,solid or powdered aluminum, copper, zinc, tin, lead, lithium, magnesium,iron, nickel, titanium, niobium, tantalum, chromium, molybdenum, cobalt,tungsten, gold, silver, platinum, and/or theirs alloys, and/ornonmetallic materials such as naturally occurring minerals and/orcompounds, ceramic particulates such as silicon carbide, boron carbide,alumina, tungsten carbide, fly ash, etc., and/or naturally occurringand/or laboratory made carbon nanotubes, graphene, graphite, andhydroxyapatite, etc., can be fed via single or multiple feedports 1124,1144 to container 1400 and/or cavity 1900. Feedstocks such as alloys,composites, organics, inorganics, polymers, and/or glass also can befed.

To consolidate malleable or deformable feedstocks in the form ofparticulates, a feedstock 1122, 1142 can be pushed into cavity 1900through more than one feedport 1124, 1144 to increase the feed rateand/or to maintain continuous operation. In certain exemplaryembodiments, extruded material 1800 of a first machine can serve asfeedstock 1122, 1142 to a second machine 1000. To produce extrudedmaterials 1800 with a refined microstructure, such as with a grain sizeranging from approximately 10 nm to approximately 100 μm, a feedstock,such as in the form of solid and/or granular materials, can be providedthrough multiple feedports 1124, 1144. Certain monolithic feedstocksused for making a composite material can be fed though together via asingle feedport 1124 or separately through multiple feedports 1124,1144. Via certain exemplary embodiments, a metal-matrix composite suchas containing ceramic particles (of single size or various sizes), e.g.,silicon carbide, boron carbide, alumina, tungsten carbide, fly ash,etc., can be embedded in aluminum, copper, lithium, magnesium, iron,nickel, titanium, niobium, tantalum, molybdenum, cobalt, and/or theiralloys, potentially with one or more reinforcement phases, can beproduced. In certain exemplary embodiments, a malleable metal alloy ofdeformable feedstock can serve as a matrix for harder reinforcementphases and/or particles to be uniformly embedded in it.

More than one type of malleable or deformable feedstock 1124, 1144 canbe fed at the same time. Depending on their compatibility, elements infeedstocks 1124, 1144, e.g., aluminum, copper, lithium, magnesium, iron,nickel, titanium, niobium, tantalum, molybdenum, cobalt, and/or theiralloys, can dissolve partially or completely in each other during theoperation, can create new phases through chemical reaction, and/or cancoexist with or without any metallurgical bonding between them. Certainexemplary embodiments can cause precipitation of dissolved elements,such as but not limited to, copper and/or silicon from aluminum, carbonfrom iron, and/or new phases before and/or after processing with and/orwithout post-processing. The alloys and/or their microstructures can befurther optimized using post-processing that involve heating, cooling,and/or plastic deformation, such as under an influence of one or moreelectrical and/or magnetic fields in an inert and/or ambient atmosphere.In certain exemplary embodiments, the extruded material 1800 can bere-processed via a method disclosed in this document and/or any otherexisting manufacturing methods such as casting, forging, rolling,machining, welding, pressing, sintering, 3D printing, etc., to generatedesired properties.

Applications of certain exemplary embodiments can include:

-   -   Refining the microstructure of the feedstock(s) 1124, 1144 using        severe plastic deformation, e.g., with a total shear strain        accumulation above 0.5, to enhance material properties such as,        but not limited to, tensile strength, yield strength, endurance        limit, hardness, wear resistance, creep resistance, electrical        conductivity, and/or thermal conductivity, etc.;    -   Achieving up to 99% reduction in cross-sectional area of a        feedstock 1124, 1144 in a single-step continuous extrusion        process;    -   Feeding and mixing ceramic and/or metallic materials to achieve        in-situ manufacturing composite material;    -   Solid-state alloying using metallic elements that are dissolved        in each other with or without the influence of severe plastic        deformation; and/or    -   Forming solid-state alloys using immiscible alloying elements        such as, but not limited to, copper and niobium, copper and        tantalum, copper and tungsten, aluminum and iron, any        combination of which can have very low solubility, such as less        than 1% at room temperature as per binary phase diagrams, in        each other and/or elements that do not form alloys in normal        circumstances. Under the application of hydrostatic pressure        above the flow stress of the feedstock 1124, 1144 and/or severe        plastic deformation these elements can dissolve in each other to        form alloys. This concept can also be applied to multiple        element system such as ternary alloy (with three elements)        systems and quaternary (four alloying element) systems, etc. In        some exemplary alloy systems, solid solubility can be further        increased under application of severe plastic deformation. The        increased solid solubility can be utilized to engineer        properties such as mechanical, electrical, thermal, chemical,        and/or electrochemical properties.    -   Producing nanostructured extruded materials 1800 with a grain        size ranging from approximately 2 nanometers to approximately        100 nanometers and/or ultrafine grained processed materials with        grainsize ranging from approximately 2 nanometers to        approximately 500 nanometers using severe plastic deformation        and/or controlled recrystallization.    -   In-situ alloying using reactive feedstocks 1124, 1144 such as,        but not limited to, aluminum and nickel, aluminum and copper,        aluminum and titanium, any of which combinations can readily        interact with each other to create an exothermic reaction. In        certain exemplary embodiments, one or more of these feedstocks        and/or combinations can be processed without melting to control        the reaction rate, such as by maintaining each element's        temperature below its melting point. The in-situ alloyed        extruded material 1800 produced using this method can be further        enhanced using heat treatment and/or other post processing        technique (note that this concept can also be applied to        multiple element system such as ternary alloy (with three        elements) system and quaternary (four alloying element) system);    -   Consolidating granular and/or discrete feedstocks 1124, 1144        including mechanically alloyed particulates, powder, granules,        machined chips, and/or swarf, etc.;    -   Producing extruded material 1800 that can serve as feedstock(s)        for welding, soldering, brazing, additive manufacturing, and/or        thermal spray applications, etc.; and/or    -   Depositing extruded material 1800 directly on to a substrate or        previously deposited layer.

The apparatus and/or tool 1000 utilized for implementation of certainexemplary embodiments can be accommodated on a small milling machinewith a working envelop of approximately 6 inches in the vertical/Zdirection without any X and Y axis movement. A standalone system 1000with an independent drive unit for material feeding, along with itscontrol system and tooling can be accommodated within an approximately0.25 m³ envelope.

Since energy can be applied and/or heat can be generated at the point ofneed, the energy loss through heat loss to the environment can beminimized. Additionally, the energy efficiency of the process can beenhanced by the solid-state nature of the feedstock(s) 1124, 1144.

Heat generated by this process can be dissipated from the surface areasurrounding rotor 1200 and/or can be recovered via internal coolingpassages in rotor 1200 and/or container 1400 and/or via an externalcooling jacket. Recovered energy can be recycled.

Certain exemplary embodiments of machine 1000 can employ continuoussevere plastic deformation to produce extruded materials 1800demonstrating microstructural refinement, composite materials,consolidated particulate materials, and/or solid-state alloys bycontinuously extruding extruded material 1800 using a rotatingnon-consumable rotor 1200 that is at least partially confined in cavity1900 that is defined within container 1400.

An exemplary embodiment is shown in FIGS. 7-11 , where an exemplaryarrangement of rotor 1200 and container 1400 is shown. Rotor 1200 can bepowered by a drive (e.g., electrically-, hydraulically-, and/orpneumatically-powered motor, rotary actuator, linear actuator, piezoelectric actuator, solenoid, etc.) and/or connected to a powered and/ordriven spindle and/or can be programmed to rotate between approximately1 rpm and approximately 10,000 rpm and/or translate in a directionparallel to rotational axis R-R and/or radially at a speed betweenapproximately 1 mm/h and approximately 100 m/h. The rotation of rotor1200 can generate a relative motion with the incoming feedstock togenerate heat and/or deformation in the direction of rotation. Rotor1200 can, but need not, have a generally conical frustum shape and/orcan be constructed with or without a shoulder. Rotor 1200 can, but neednot, have and/or define geometrical and/or mechanical features, such asone or more fins, flutes, flats, slots, threads, steps, nubs, buttons,and/or protrusions on one or more exterior surfaces and/or one or moreinterior surfaces of rotor 1200. As shown in FIGS. 103-105 , when rotor1200 is viewed along rotational axis R-R from its distal terminus, rotor1200 (e.g., semi-contained portion 1240 and/or contained portion 1260)can define a visible proximal perimeter or optical projection 1288 thatis located a selected distance toward the proximal end of rotor 1200with respect to distal terminus 1285. The length of visible proximalperimeter 1288 can be greater than the length of a visible distalperimeter or optical projection 1286 defined by distal end portion 1280.Stated differently, looking along rotational axis from distal terminus1285, an annular portion 1289 of rotor 1200 can be visible, that annularportion 1289 located closer to the proximal end of rotor 1200 withrespect to distal terminus 1285. The existence of this visible annularportion 1289 can geometrically indicate that stirred material 1800 canbe operatively forced, by the rotation of rotor 1200, from, e.g.,feedport exit 1126, toward the distal end of rotor 1200 and/or towarddie 1500, even if stirred material sticks to rotor 1200 and/or goesunwiped from rotor 1200. That is, this geometry can indicate that thereis more surface area having a component facing toward the distal endthat is available to apply distally-directed pressure to stirredmaterial 1700 than there is surface area having a component facingtoward the proximal end to apply a proximally-directed pressure, suchthat rotor 1200 operatively applies a net positive distally-directedpressure to stirred material 1700.

Container 1400 can define at least one cavity 1900 to accommodate atleast a contained portion 1260 of rotor 1200, any semi-contained portion1240 of rotor 1200, at least one feedport 1124, 1144, a die 1500, and/ora container exit 1480. The die can, but need not, be an integral part ofcontainer 1400. Container 1400 can be stationary and/or rigidly fixed toa mounting platform and/or frame 1660 using one or more of mountingbrackets and/or mounting fasteners. Container 1400 can, but need not,have cavity-facing and/or externally facing features, such as one ormore fins, flutes, threads, steps, nubs, buttons, and/or protrusions,which can be configured to control the material flow direction. Anyfeedport 1124, 1144 can be the pathway for the feedstock to enter intocavity 1900, where rotor 1200 can rotate and/or can translate in apredefined direction, pattern, and/or path, such as around and/or alongits rotational axis. This movement of rotor 1200 can dynamically changea magnitude of the radial gap GR and/or axial gap GA between container1400 and rotor 1200, such as at the feedport exit 1126, 1146.Translation is not necessary if rotor 1200 is designed in such a waythat the magnitude of the radial gap GR and/or axial gap GA dynamicallychanges upon rotation of rotor 1200. For example, if rotor 1200 iseccentric and/or out of balance about its rotational axis R-R and/or ifrotor 1200 and/or contained portion 1260 has certain external surfacefeatures, such as those shown in FIGS. 30-39 , the magnitude of theradial gap GR and/or axial gap GA can change during rotation. Such gapchanges can urge feedstock 1122, 1142 and/or stirred material 1700toward die 1500. More generally, gap changes that can create suchmovement of feedstock 1122, 1142 and/or stirred material 1700 can be dueto radial wobble, vibration having a radial and/or axial component,and/or surface geometry, etc. Moreover, drive 1300 can be configured tomove rotor 1200, rotationally and/or axially, in a continuous, cyclical,controlled, timed, periodic, aperiodic, and/or reciprocating manner.Axial motion of rotor 1200 can be created by interactions betweenfeedstock 1124, 1144 and rotor 1200. For example, as feedstock 1122,1142 enters cavity 1900, it can intermittently encounter a rotatingfeature on rotor 1200, that encounter causing periodic forces, acomponent of which can be aligned parallel to the rotational axis, to beapplied to feedstock 1122, 1142 and/or corresponding reaction forces onrotor 1200. When the magnitude of the radial gap GR and/or axial gap GAincreases, the feedstock 1122, 1142 can enter cavity 1900 via feedstockexit 1126, 1146. During this process, entering feedstock can contactand/or fully or partially remove stirred material that is sticking tothe exterior surface of rotor 1200. When the magnitude of the radial gapGR and/or axial gap GA decreases, rotor 1200 can apply a force on,deform, mix, consolidate, and/or move the stirred material 1700 towardsdie 1500 and/or container exit 1480, and/or can decrease and/or blockthe flow of feedstock 1122, 1142 into cavity 1900.

As shown in FIG. 7 , feeder 1120 can comprise a feedport opening 1121and/or a feed mechanism 1123, 1143. Feedstock 1122 can enter feedport1124 through feedport entrance 1121 and/or feed mechanism 1123 can movefeedstock 1122 through feedport 1124 towards cavity 1900 and out offeedport 1124 through feedport exit 1126. In certain exemplaryembodiments, a feedport can have any cross-sectional shape. In certainexemplary embodiments, a feedport can be narrower, as measuredperpendicular to the rotational axis R-R of rotor 1200, than the reachand/or maximum outer radius of rotation of rotor 1200. In certainexemplary embodiments, the dimensions of the feedport can be selected toprevent the feedstock from entering cavity 1900 in a manner, location,and/or orientation that the feedstock would avoid contact with and/orbypass rotor 1200 without being plastically deformed. One or morefeedstocks in non-liquid state and/or a solid-state can be fed throughone or more feedports together or separately. For example, discretesolid-state feedstocks such as, but not limited to, powder, pellets,chunks, and/or agglomerates, and/or continuous solids such as rods,wires, and/or tubes with fillings, can be fed through one or morefeedports together or separately. One feedstock can be malleable and/ordeformable at a temperature between room temperature and the meltingpoint of that feedstock. A feed mechanism can be chosen according to thefeedstock requirement. For example, for a discrete solid feedstock areciprocating piston-type feeding mechanism can be used as shown inFIGS. 7, 8, and 10 . For continuous feeding of a solid feedstock, apinch roller-type feeding mechanism, as shown in FIG. 9 , and/or agear-type mechanism, can be used. For feedstocks such as powder metals,ceramic powder, fly ash, swarfs, pellets, etc., an Archimedesscrew/auger-type feeding mechanism, as shown in FIG. 11 , and/or apiston-type feeding mechanism can be used separately or in combination.

Rotor 1200 and/or container 1400 can have various surface features suchas fins, flutes, slots, threads, steps, nubs, buttons, protrusions,and/or predetermined geometries. The dimensions of container 1400,cavity 1900, and/or feedport 1124, 1144 can be related to the dimensionsof rotor 1200. To avoid contact between rotor 1200 and container 1400,within a given horizontal plane that cuts perpendicularly throughrotational axis R-R, while rotor 1200 is rotating and/or translating,the inner diameter of container 1400 can be larger than the outerdiameter of the contained portion 1260 of rotor 1200 by approximately0.1 mm to approximately 100 mm. The overall length of container 1400 canbe shorter or longer than rotor 1200 as a whole and/or than the combinedlength of semi-contained portion 1240 and contained portion 1260 ofrotor 1200. A feedport can be as wide as the width of rotor 1200 and/ornarrower than that width at any given location of feedport. Themagnitude of the radial gap GR between rotor 1200 and container 1400'sinterior side wall can vary along the axial direction (i.e., can varyfrom one horizontal plane that cuts perpendicularly through rotationalaxis R-R and another such plane) and/or can be between approximately 0.1mm and approximately 100 mm.

The magnitude of the radial gap GR or the axial gap GA can be as smallas zero when rotor 1200 is inserted into container 1400 sufficientlythat rotor 1200 contacts container 1400. If enough of rotor 1200 isremoved from container 1400, such that none of the contained portion1260 of rotor 1200 is below the centroid of feedport exit 1126, theradial gap GR might grow to half the width of cavity 1900, which wouldextend radially across the entire inside of container 1400.

The overall angle of container 1400's interior side wall can be and/orvary between approximately 0° and approximately 45° with respect torotor 1200's rotational axis R-R, and/or locally can be and/or varybetween approximately 0° and approximately 90° with respect to rotor1200's rotational axis R-R at any point along that axis. The overallangle of rotor 1200's side wall angle can be and/or vary betweenapproximately 0° and approximately 45° with respect to rotational axisR-R, and/or locally can be and/or vary between approximately 0° andapproximately 90° with respect to rotor 1200's rotational axis R-R atany point along that axis. The exterior wall(s) of rotor 1200 and theinternal wall(s) container 1400 need not be parallel to each other.

As shown in FIGS. 20-29 , rotor 1200, cavity 1900, container 1400,and/or die 1500 can be configured to produce a predetermined geometryfor the extruded material. Examples of rotor and containerconfigurations that can be used to produce rods and/or wires are shownin FIGS. 20 and 21 . At die 1500 and/or container exit 1480, rotor 1200can be configured in such way that extruded material 1800 is fullyconsolidated. The distance between the exit of die 1500 and the end ofrotor 1200, the rotational speed of rotor 1200, and/or the feedstockfeed rate can be varied between approximately 1 mm and approximately 100mm, between approximately 1 rpm and approximately 10,000 rpm, and/orbetween approximately 1 mm/min and approximately 10,000 mm/min,respectively, to control the consolidation efficiency for a givencombination of feedstock(s), rotor 1200, and/or container 1400.

FIGS. 28, 29, and 97-102 show example configurations of rotor 1200,container 1400, and substrate 1620, upon which extruded material can bedeposited. A rotor with distal end portion 1280, such as shown FIGS. 46and 47 , can used for depositing extruded material 1800 onto substrate1620 as deposited material 1680. The rotor end portion 1280 can touchsubstrate 1620 and/or generate frictional heat, deform the surface ofsubstrate 1620, and/or break a contaminated and/or oxidized layer on thesurface of substrate 1620. During this process, extruded material 1800can flow within the encircled area of the end portion and/or fill thespace between substrate 1620 and rotor 1200. As shown in FIG. 99 , upona relative movement of substrate 1620 and container 1400, extrudedmaterial 1800 can be deposited onto substrate 1620 as deposited material1680. The deformation and/or heat generated by the rotary motion ofrotor 1200's distal end portion 1280 under a hydrostatic pressure cancause some extruded material to flow in front of the distal end portion1280 in the direction of its relative movement and/or produce ametallurgical bonding between deposited material 1680 and substrate1620.

FIGS. 22 and 23 show an example configuration of rotor 1200 andcontainer 1400 for producing extruded material 1800 in tube and/or pipeform where an annular cross-sectional shape (i.e., defining an innerspace of the extruded material that is circular or any closed polygonalshape, such as oval, triangular, rectangular, square, hexagonal, etc.)can be defined between rotor 1200 and the exit of die 1500 and/orapplied via tool 1000 to extruded material 1800. The inner and/or outerdiameters of that, e.g., annular, shape can define the dimensions of thecross-section of the produced annular tube and/or pipe. FIGS. 86 and 87show an example configuration of a rotor 1200 and container 1400 forproducing materials in tube, pipe, and/or wire form 1850 with internalfilling 1150 in them, that filling 1150 being one or more fluxes,metals, alloys, and/or ceramics. Such tubes, pipes, and/or wires 1850can be produced in any length, and/or can be used as filler rods forjoining, welding, overlaying/cladding, and/or thermal and/or cold spraycoating. Secondary phases with higher electrical and/or thermalconductivity, such as graphene and/or carbon nano-tubes, and/or silverand copper, can serve as a filling 1150 in lower conductivity tubes 1850to enhance electrical and/or thermal conduction. Super-conductingmaterials that are very brittle and/or harder to processes can be serveas a filling 1150 in metallic alloy tubes 1850 for ease of handlingand/or further processing. Ceramic particles and/or fibers of varioussizes can serve as a filling 1150 that can stiffen and/or strengthen anextruded tube 1850. Radioactive, toxic, and/or corrosive fillingmaterials 1150 can be safely stored by placement within a closed,extruded tube 1850 for an extended period of time. The above-mentionedapplications can be performed with or without any post-processmanufacturing steps such as heat treatment, wire drawing, machining,and/or grinding, etc. To prevent a filling from falling out, an extrudedtube, pipe, and/or wire 1850 can be crimped and/or plugged at one orboth ends. Filling 1150 can be fed into tube, pipe, and/or wire 1850through a conduit 1290 defined in a rotor passage 1295 located in acenter and/or interior of rotor 1200.

In certain exemplary embodiments, rotor passage 1295 can serve as aback-extrusion channel via which stirred material and/or extrudedmaterial flows toward the proximal/driven end of the rotor.

In certain exemplary embodiments, rotor 1200, container 1400, and/or die1500 can cooperate to apply to extruded material 1800 any desiredcollapsed and/or non-polygonal cross-sectional shape, such as ell,channel, T, I, etc.

Machine 1000 can utilize any number of feeders, feedports, dies, and/orcontainer exits. For example, FIG. 15 shows an exemplary configurationhaving multiple dies 1500 and container exits 1480. A feedport, die,and/or container exit can be oriented at an angle between 0° and 90° tothe rotational axis R-R of rotor 1200 as measured with respect to aplane that perpendicularly intersects axis R-R.

Machine 1000 can be positioned in any orientation such that rotationalaxis R-R is at any angle with respect to a horizontal plane. Since thefeedstock can be plastically deformed, be embedded and/or dispersed in aplastically deformed material, and/or react and/or alloy with aplastically deformed material, the orientation of axis R-R need notadversely affect the operation of machine 1000. However, the feedportorientation might need to be adjusted based on the feedstock andorientation of axis R-R.

FIGS. 22 and 23 show an exemplary embodiment where severe plasticdeformation, microstructural modification, consolidation, and/orextrusion can happen cyclically. In each cycle, a solid, powder, and/orgranular feedstock 1122, 1142 can be consolidated, dispersed, alloyed,and/or extruded. This process can be applicable for processing hightemperature feedstocks such as iron, nickel, cobalt, zirconium, and/ortungsten, and/or their alloys and/or composites. At step 1, for thosefeedstocks that might fall through cavity 1900 and die 1500, a piece ofsolid feedstock that is from approximately 0.1 mm to approximately 10 mmwider than the largest dimension of die 1500, and that has beenpre-placed in container 1400, can be stirred to cover the die opening,which can support the compressive forces needed to compact and/orconsolidate the powder and/or granular feedstock. At step 2 of thecycle, rotor 1200 can be partially retracted from container 1400 toexpand cavity 1900 and/or to open one or more feedports 1124, 1144. Oneor more feedstocks 1122, 1142 can be pushed into a correspondingfeedport 1124, 1144 using, e.g., a screw conveyer and/or piston-typepush rod, and then on into container 1400 and/or cavity 1900. At step 3,the rotating rotor 1200 can be plunged into container 1400 to compressthe feedstock 1122, 1142 within cavity 1900. During this step frictionaland/or adiabatic heat (i.e., heat occurring in essentially only thestirred material due to deformation and/or with no appreciable heatingof the rotor and/or container) can be generated, along with an intenseshear deformation, which can be sufficient to generate conformal contactbetween the particles of the feedstock. The shear deformation undercompressive forces can create metal-to-metal contact between theparticles and/or with a previously consolidated feedstock. During thisoperation any contaminated and/or oxidized layer on the surface of thefeedstock can be broken to establish a metal-to-metal contact. Uponfurther plunging of rotor 1200 the consolidated stirred material 1700can be extruded through the die with further reduction in cross section.During this step the feed tube can be filled from the powder hopperand/or degassed with the help of the process heat. At the end of step 3rotor 1200 can be retracted and/or cooled. Steps 2 and 3 can be repeatedto continuously create consolidated and extruded material 1800. Theentire process can happen in an inert argon atmosphere, potentiallyunder a slightly positive pressure, to avoid oxidation of the feedstock1122, 1142, stirred material 1700, and/or extruded material 1800 and/orto ensure safe operation.

FIGS. 40-63 show some exemplary geometries for distal end portion 1280of an exemplary rotor 1200. Any of these geometries can used to aid theflow of stirred material 1700 through cavity 1900 to die 1500. Thegeometries at the distal end portion 1280 of rotor 1200 can causeadditional mixing prior to extrusion and/or can generate additionalpressure and/or temperature to ease the stirred material 1700 throughthe die. Distal end portion 1280 can include and/or define, e.g., nubsand/or protrusions, which can increase rotor 1200's mixing capabilityand/or can be used in composite material manufacturing to create asubstantially uniform microstructure in the extruded material 1800.Rotor 1200 and/or container 1400 can have and/or define variousgeometric features, such as fins, flutes, flats, slots, threads, steps,nubs, buttons, and/or protrusions, on their exterior surfaces and/orinterior surfaces.

As shown in FIGS. 64-84 , container 1400 can have and/or define any of awide variety of geometric features, which in some embodiments can definethe shape of cavity 1900. For example, container 1400 can define stepsand/or stairs, a smooth transition to the die, steps and/or transitionsmade of different materials, can be contained in a separate structuresuch as container housing 1440, a die 1500 contained in anotherstructure such as die plate 1520, a die 1500 made of another material, adie 1500 attached to container 1400, a top portion of container 1400made of another material, and/or compared to rotor 1200 and/or theremainder of container 1400, the cavity-facing inner surface 1420 ofcontainer 1400 can have a different material and/or texture, such ascoated, polished, honed, ground, machined, sand blasted, shot peened,laser engraved, and/or hammered compared to another surface of container1400 and/or a surface of rotor 1200, such as an exterior surface ofsemi-contained portion 1240, contained portion 1260, and/or distal endportion 1280. A smooth geometric transition in and/or on thecavity-facing interior surface of container 1400 and/or such an outersurface of rotor 1200 can be beneficial in processing monolithicfeedstocks. Steps and/or stair features in and/or on the interiorsurface of container 1400, possibly created by forming container 1400from multiple layers 1460, can increase material mixing capability. Theshape and/or size transitions of container 1400 and/or rotor 1200 canavoid rotor breakage by distribution of the stress on rotor 1200.Container 1400 being directly in contact with feedstock 1122 and/orstirred material 1700 can provide high temperature stability such aswhen container 1400 and/or semi-contained portion 1240, containedportion 1260, and/or distal end portion 1280 of rotor 1200 is made fromand/or coated with refractory metals and/or their alloys and/or ceramicmaterials, and even from those materials, alloys, solid-state solutions,and/or composites that lack toughness. In such cases, the cavity-facinginner surface 1420 of container 1400 can be coated with and/or containedin a tougher material. In certain exemplary embodiments, the material ofcontainer 1400, semi-contained portion 1240, contained portion 1260,distal end portion 1280, and/or feedstock(s) 1122, 1142 can be paired toreduce or increase friction between them due to adhesive nature of theirmaterials to each other. The texture and/or roughness of one or morecavity-facing interior surfaces 1420 of container 1400, semi-containedportion 1240, contained portion 1260, and/or distal end portion 1280 canbe configured to increase and/or decrease the friction generated withincavity 1900 due to the ploughing nature of a harder material into softermaterials. Similarly, the friction condition and/or coefficient can bemodified using different materials and/or surface textures for container1400, semi-contained portion 1240, contained portion 1260, and/or distalend portion 1280. Container 1400 can be manufactured with integralcomponents such as feedport and/or die, or the die and/or feedport canbe separate components configured to be attached to container 1400. Incertain exemplary embodiments, all or any portion of rotor 1200, such assemi-contained portion 1240, contained portion 1260, and/or distal endportion 1280, and/or container 1400 can be made using one or morematerials, such as tool steels, stainless steels, nickel alloys, cobaltalloys, tungsten alloys, rhenium alloys, and/or their composites, and/orcarbide, nitrides, and/or oxides of various elements such as cubic boronnitride, silicon carbide, tungsten carbide, titanium carbide, titaniumnitride, alumina, zirconia, etc., and/or coatings such as thermal spraycoatings, physical and or chemical vapor-deposited coatings, includingdiamond-like carbon coatings, and/or titanium nitride, etc. Rotor 1200,semi-contained portion 1240, contained portion 1260, distal end portion1280, and/or container 1400 can have one or more internal coolingarrangements such as cooling passages for any coolants and/or can bemade of highly conductive material such as aluminum, copper, silver,and/or gold configured to enhance heat extraction, heat transfer,cooling, and/or heating, such as via resistive heating, inductiveheating, convective heating, and/or infrared heating, etc.

Certain exemplary embodiments can be configured for feeding a solidfeedstock of predetermined maximum length using an existing machine toolwith a rotating spindle. In certain exemplary embodiments, such as shownin FIG. 6 , a feeder frame 1670 can be constructed using two frameshafts and two frame bars. One end of a piston type push rod can beconnected to the frame bars and the other end of the push rod can befree to move inside the feedport. One side of feeder frame 1670 can beattached to a reciprocating motion generation device through a loadcell. The stroke length and/or speed of the reciprocating motion can beprogrammable. When the motion is created, the feeder frame 1670 can moveone of push rod towards the container, and/or the other away from thecontainer. The push rod moving away from the container can open thefeedport opening. When the feedport opening is sufficiently opened, asolid feedstock rod can fall inside the feedport and/or the motion offeeder frame 1670 can be reversed. The push rod can move the feedstocktowards the container, during which time the applied force on thefeedstock can be measured by the load cell and/or a feeding rate can becalculated and/or recorded in a data-logging device in the controlsystem. The reciprocating motion is illustrated as being created bylinear electrical actuator, but the motion can be created by anyactuation means such as, but not limited to, pneumatic and/or hydraulicactuators. In certain exemplary embodiments, when severe plasticallydeformed material, composite, consolidated powder, and/or solid-statealloyed material is generated and/or extruded, the extruded materialand/or processed material can be deflected by a deflector to apredetermined direction.

In certain exemplary embodiments, a reversible container can beconfigured to be split into two halves, which can be aligned forreassembly using one or more alignment pins. The container can be madeto split and/or separate in any orientation such as parallel,perpendicular, and/or at an angle to the rotational axis of the rotor.Having the ability to split and/or separate can allow access to thecavity and/or interior portion of the container for cleaning and/orfixing. Similarly, the ability for the rotor to be made of multiplematerials and/or components can help optimize the manufacturing costand/or performance.

In certain exemplary embodiments, the contained portion of the rotor canbe generally frustum shaped and/or can have an approximately 0.5 mm toapproximately 500 mm top diameter at the proximal end, and approximately0 mm (i.e., a sharply pointed end) to approximately 490 mm diameter atthe distal end, and/or approximately 1 mm to approximately 1000 mm inlength, and/or can have a stepped spiral feature on its outer surfacewith an approximately 0.1 mm to 100 mm depth and/or an approximately 0.1mm to approximately 100 mm pitch. The container can have an outsidediameter of approximately 1 mm to 700 mm and/or an overall length ofapproximately 10 mm to 1000 mm.

Referring to FIGS. 20-29 , from the perspective of drive 1300, adjacentto drive 1300 (which can include any spindle, coupling, gearbox,transmission, or other mechanism connecting a source of rotationaland/or translational power to rotor 1200), in certain exemplaryembodiments, rotor 1200 can define a proximal shoulder, shank, and/ornon-contact portion 1210 configured to operatively connect to a spindleand/or drive shaft and/or configured to not operatively contactfeedstock and/or stirred material. Adjacent to proximal non-contactportion 1210, rotor 1200 can define a proximal contact portion 1220 thatcan operatively contact feedstock and/or stirred material but notoperatively enter container 1400. Adjacent to contact portion 1220,rotor 1200 can define a semi-contained portion 1240 configured tooperatively enter and exit container 1400. Adjacent to semi-contactportion 1240, rotor 1200 can define a contained portion 1260 configuredto operatively remain in container 1400. Adjacent to contained portion1260, rotor 1200 can define a distal end portion 1280 configured tooperatively interface with die 1500 to define a longitudinalcross-sectional shape of extruded material 1800.

As shown in FIGS. 67-69 , container 1400 can be designed to bereversible, having two opposing internal cavities, e.g., one on the topand other in the bottom, each of which, by itself, can accommodate arotor 1200. The dimensions of the cavities, which can be cooperativewith rotor 1200, can be approximately 1 mm to 500 mm in internaldiameter at the widest location and/or approximately 0.01 mm to 250 mmin internal diameter at the narrowest location. In certain exemplaryembodiments, a passage can connect these two cavities, and/or thispassage can act as a die during the operation. Cavity 1900 can besymmetric about the rotational axis of rotor 1200. Container 1400 can besymmetric about its mid-plane perpendicular to the rotation axis. Thiscan allow container 1400 to be used from both sides of the die.

Rotor 1200 and/or container 1400 can be manufactured using a CNCmachining and/or grinding operation. Rotor 1200 and/or container 1400can be made of, e.g., H13 tool steel, which can be pre-annealed and/orheat treated after manufacturing using one or more heat treatment cyclesinvolving solutionizing, air cooling, and/or tempering.

As shown in FIGS. 91-93 , certain exemplary embodiments of machine 1000can utilize multiple rotors 1200 that each rotate within, and/ortranslate at least partially in and out of, a single common container1400. In certain exemplary embodiments, a multi-rotor machine canutilize two opposing rotors, each having its own die, the extrudedmaterial from which leaves the container via a common exit. In certainexemplary embodiments, a multi-rotor machine can utilize a single commoncontainer within which can operate two opposing rotors, each opposingrotor fed by its own feedport and rotating within its own cavity.Stirred material can exit those cavities via a tube in one or more ofthe rotors, thereby allowing for back-extrusion through each such rotor.

As shown in FIGS. 91-93 , certain exemplary embodiments of machine 1000can provide for a single common container 1400 within which multiplerotors 1200 can operate. These rotors can, but need not, be opposing.For example, two rotors 1200 can oppose one another along a common firstrotational axis, and another two rotors can oppose one another along acommon second rotational axis that can be, e.g., coincident,non-coincident, parallel, non-parallel, angled, perpendicular, etc. withthe common first rotational axis. A fifth rotor can rotate along a thirdrotational axis that can be, e.g., coincident, non-coincident, parallel,non-parallel, angled, and/or perpendicular, etc. with respect to thecommon first rotational axis and/or the common second rotational axis.Any number of feedstocks 1122, 1142 can be provided via any number offeedports 1124, 1144 to any number of cavities within which stirredmaterial 1700 can be formed. Extruded material 1800 can pass through anynumber of dies 1500 and/or can leave the container via any number ofcontainer exits 1480.

Certain exemplary embodiments can be configured to extrude solidaluminum alloy filler feedstocks continuously. Feedstock can be fedusing a piston mechanism that can be connected to a reciprocating linearmotion-producing electrical cylinder. Certain exemplary embodiments canconnect the reciprocating piston mechanism to the electrical cylinder.In this arrangement, the feedport ends can be rigidly mounted on to afixture while the shaft of the feeder frame 1670 and/or push rod canslide freely through the fixture. In certain exemplary embodiments,solid feedstock can be loaded onto a cartridge.

Certain exemplary embodiments can provide for feeding similar feedstocksin any non-liquid form, such as granular materials, ball milled powders,chopped wires, and/or metal shavings etc., through one or multiplefeedports and extruding through singular or multiple die exit tocontinuously produce severe plastically deformed processed material,microstructurally refined materials, and/or billets, such as via thefollowing process steps:

Certain exemplary embodiments can provide for feeding dissimilarfeedstocks in any non-liquid form through one or multiple feedportsand/or extruding through singular and/or multiple die exit tocontinuously produce composite materials, solid-state alloys, in-situcomposites, and/or in-situ alloys.

The desired rotation speed, translation distance, speed of rotor, and/orfeedstock feed rate can be controlled through a control system. Based onthe measured forces, torques, and/or temperatures, process parameterssuch as rotation speed, translation speed, and/or feedstock feed ratecan be varied. In certain exemplary embodiments, the parameters can befed to the control system through a human-machine interface, such as toa computer and/or corresponding software program. The control system cancommunicate with the drive, spindle, and/or feeding drive units whilemonitoring and/or recording, e.g., the position of rotor 1200, thetemperature of container 1400, and/or the temperature and/or flowrate ofextruded material 1800, forces on the spindle and/or feeding system,spindle torque, speed of rotation, and/or translation distance and/orrate of change of the speed of rotor 1200 and/or feedstock, etc.Additional capabilities such as but not limited to cooling, heating,and/or energy recovery and/or recycling units can be added to thesystem.

Referring to FIG. 85 , certain exemplary embodiments can provide aprocess and/or method 10000, which can comprise any of the followingactivities:

-   -   At activity 10100, desired component parameters (e.g., types of,        e.g., feeders, rotors, containers, and/or dies; sizes and        dimensions; materials; properties; etc.), feedstock parameters        (e.g., shape, form, and/or properties of feedstocks), extruded        material parameters (e.g., shape, form, and/or properties of        extruded material), and/or process parameters (e.g., feedstock        flowrates, rotational speed, translation speed, translation        distance, feed pressure, and/or cavity temperature, etc.) can be        selected;    -   At activity 10200, each desired feedstock can be provided to a        corresponding feeder;    -   At activity 10300, feedstock can be fed into the cavity;    -   At activity 10400, while monitoring, adjusting, and/or        controlling process parameters, the rotor can be moved (e.g.,        rotated and/or translated) to convert and/or process the        feedstock(s) into a stirred material, e.g., via severe plastic        deformation, chemical reaction, alloying, compositing, bonding,        consolidating, melting, segregation, partitioning,        precipitating, etc.);    -   At activity 10500, the stirred material can be forced through a        die, such as via forward extrusion and/or back-extrusion, to        form extruded material; and/or    -   At activity 10600, the extruded material can be post-treated        and/or post-processed (via e.g., cutting to length, stretching,        drawing, cooling, heating, 3-D printing, depositing, bonding,        heat treating, pickling, anodizing, galvanizing, oxidizing,        machining, finishing, coating, painting, insulating,        magnetizing, marking, re-processing, recycling, assembling,        packaging, etc.) as desired.

In certain exemplary embodiments, parameters (e.g., feedstocks, processvariables, etc.) can be varied and/or controlled to impart a change in aproperty of extruded material 1800 along a longitudinal axis of thatmaterial. That is, there can be a difference in properties between anextruded material that exits die 1500 slightly before extruded materialextruded from the same machine 1000, that later extruded material atleast initially connected to the earlier extruded material as the latermaterial is extruded from machine 1000.

In certain exemplary embodiments, the geometry of the contained portion1260, the geometry of container inner surface 1420, the wipingmechanism, and/or the movement of rotor 1200 can be configured to causestirred material to advance toward die 1500 in a manner that creates asteady state operating condition for machine 1000 that is defined by apositively-valued (i.e., non-zero) and uniform average flowrate ofextruded material 1800 out of machine 1000, that average calculated overa predetermined time interval selected from a range of 1 second to 3minutes, such as 2 seconds, 10 seconds, 20 seconds, 1 minute, 2 minutes,etc. Thus, at steady state, regardless of whether feedstock 1122, 1142enters cavity 1900 continuously, intermittently, and/or cyclically,and/or whether rotor 1200 axially translates, reciprocates, and/oroscillates, and/or whether rotor 1200 radially wobbles, and/or rotor1200 moves in any non-uniform manner during a smaller time interval,extruded material 1800 can flow continuously and/or uniformly frommachine 1000 according to the just-described predetermined averagingtechnique. At steady state, the combined average flowrate of allextruded material 1800 from machine 1000 can be non-zero and equal tothe combined average flowrate of all feedstocks entering cavity 1900,such that the steady state operating condition of machine 1000 canextend for a predetermined time ranging from 1 minute to 100 hours (ormore).

Certain exemplary embodiments can provide a method for producing anextruded material from one or more feedstocks, the method comprisingperforming the activities of:

-   -   feeding a deformable solid-state first feedstock selected from        the one or more feedstocks through a stationary first feedport        and into a cavity defined between a rotor and an inner wall of a        stationary container;    -   upon contacting the first feedstock with the rotor, without        melting the first feedstock, creating a stirred material within        the cavity via activities comprising plastically deforming the        first feedstock;    -   continuously extruding the stirred material from the cavity        through one or more dies to generate an extruded material;    -   during the feeding of the first feedstock into the cavity,        wiping a portion of the stirred material from the rotor;    -   during the feeding of the first feedstock into the cavity,        feeding a second feedstock selected from the one or more        feedstocks through a stationary second feedport and into the        cavity;    -   incorporating the second feedstock into the stirred material;    -   dividing the second feedstock;    -   within the cavity, reacting the second feedstock with the first        feedstock;    -   metallurgically and seamlessly bonding the stirred material        within the cavity;    -   consolidating the stirred material within the cavity;    -   causing the stirred material to undergo melting, segregation,        partitioning, or precipitation;    -   depositing the extruded material onto a substrate;    -   bonding the extruded material to a substrate; and/or    -   during the plastically deforming activity, alloying the first        feedstock with a second feedstock selected from the one or more        feedstock;    -   wherein:        -   the rotor defines a rotational axis about which the rotor is            configured to operatively rotate;        -   the rotor defines a contained portion that operatively            remains within the container;        -   the first feedstock is fed through the stationary first            feedport while the contained portion of the rotor is            operatively rotating;        -   the contained portion has a generally conical frustum shape            that defines a proximal end and a distal end, the proximal            end located closer to a driven portion of the rotor than the            distal end;        -   while the contained portion is operatively rotating:            -   a magnitude of an axial gap continuously changes across                time, the axial gap measured along a first line                extending in a predetermined perpetual cross-sectional                plane that includes the rotational axis, the first line                extending parallel to the rotational axis, the gap being                the shortest distance, on the predetermined perpetual                cross-sectional plane and along the first line,                between (a) the exterior surface of the rotor and (b) a                second line that extends in the predetermined perpetual                cross-sectional plane, is perpendicular to the                rotational axis, and intersects a centroid of an exit of                the first feedport; and/or            -   a magnitude of a radial gap continuously changes across                time, the radial gap measured along the second line and                being the shortest distance, on the predetermined                perpetual cross-sectional plane and along the second                line, between the exterior of the rotor and the first                line;        -   as viewed along the rotational axis from the distal end, a            visible proximal perimeter of the rotor located proximal            from the distal end is greater than a visible distal            perimeter of the rotor located at the distal end;        -   said feeding activity occurs continuously, cyclically,            and/or reciprocatingly;        -   said extruding activity comprises back-extruding the            extruded material through the rotor;        -   the rotational axis is configured to operatively wobble            while the rotor is rotating;        -   the rotor does not operatively effect the activity of            feeding the first feedstock when the contained portion            operatively translates along the rotational axis;        -   the contained portion is configured to operatively oscillate            along the rotational axis;        -   the contained portion is configured to operatively            reciprocate along the rotational axis;        -   the rotor is configured to operatively change the volume of            the cavity while the rotor is operatively translating along            the rotational axis of the rotor;        -   the rotor defines one or more fins, flutes, flats, slots,            steps, stepped spirals, nubs, buttons, cutting edges, and/or            protrusions;        -   the inner wall of the container defines one or more fins,            flutes, flats, slots, steps, stepped spirals, nubs, buttons,            cutting edges, and/or protrusions; the first feedstock            enters the cavity in direction non-parallel to the            rotational axis;        -   the extruded material is extruded through the die in            direction non-parallel to the rotational axis;        -   the rotor and the die are configured to cooperatively impose            an elongated form onto the extruded material, the elongated            form having an annular shape;        -   a composition of the extruded material varies along a            longitudinal axis of the extruded material;        -   at least one property of the extruded material varies along            a longitudinal axis of the extruded material;        -   at least one feedstock from the one or more feedstocks is in            the form of particulates, powder, granules, machined chips,            and/or swarfs;        -   at least one feedstock from the one or more feedstocks            comprises a metal, alloy, ceramic, polymer, or glass;        -   the extruded material has the general form of a pipe, tube,            wire, rod, sheet and or channel;        -   the extruded material has the form of a pipe or tube filled            with a material other than the extruded material;        -   the extruded material comprises a pure metal, an alloy,            and/or a composite; and/or        -   the extruded material has a microstructure defined by            substantially uniform distribution of grain structure and            one or more secondary phases;

Certain exemplary embodiments can provide a method for producing anextruded material from one or more feedstocks, the method comprisingperforming the activities of:

-   -   feeding a deformable solid-state first feedstock selected from        the one or more feedstocks through a stationary first feedport        and into a cavity defined between a rotor and an inner wall of a        stationary container;    -   upon contacting the first feedstock with the rotor, without        melting the first feedstock, creating a stirred material within        the cavity via activities comprising plastically deforming the        first feedstock; and/or    -   continuously extruding the stirred material from the cavity        through one or more dies to generate an extruded material;    -   wherein:        -   the rotor defines a rotational axis about which the rotor is            configured to operatively rotate;        -   a contained portion of the rotor is configured to            operatively remain within the container while operatively            translating along the rotational axis;        -   the first feedstock is fed through the stationary first            feedport while the contained portion is operatively            rotating;        -   the rotor defines a semi-contained portion located            immediately adjacent to the contained portion;        -   the rotor defines a contained perimeter located in a plane            that is oriented perpendicularly to the rotational axis and            that separates the contained portion from the semi-contained            portion;        -   the semi-contained portion operatively enters and exits the            container;        -   the feeding activity is operatively halted when the            semi-contained portion begins entering the container;        -   the contained portion has a generally conical frustum shape            that defines a proximal end and a distal end, the proximal            end located closer to a driven portion of the rotor than the            distal end;        -   while the contained portion is operatively rotating and            translating:            -   a magnitude of an axial gap continuously changes across                time, the axial gap measured along a first line                extending in a predetermined perpetual cross-sectional                plane that includes the rotational axis, the first line                extending parallel to the rotational axis, the gap being                the shortest distance, on the predetermined perpetual                cross-sectional plane and along the first line,                between (a) the exterior surface of the rotor and (b) a                second line that extends in the predetermined perpetual                cross-sectional plane, is perpendicular to the                rotational axis, and intersects a centroid of an exit of                the first feedport; and/or            -   a magnitude of a radial gap continuously changes across                time, the radial gap measured along the second line and                being the shortest distance, on the predetermined                perpetual cross-sectional plane and along the second                line, between the exterior of the rotor and the first                line; and/or        -   as viewed along the rotational axis from the distal end, a            visible proximal perimeter of the rotor located proximal            from the distal end is greater than a visible distal            perimeter of the rotor located at the distal end.

Certain exemplary embodiments can provide a machine configured forproducing an extruded material from one or more feedstocks, the machinecomprising:

-   -   a feedstock feeder that operatively feeds a deformable        solid-state first feedstock selected from the one or more        feedstocks through a stationary first feedport and into a cavity        defined between a rotating rotor and an inner wall of a        stationary container;    -   a rotor that, upon contacting the first feedstock with the        rotating rotor and without melting the first feedstock,        operatively creates an unmelted stirred material within the        cavity via activities comprising plastically deforming the first        feedstock;    -   a translatable feeder frame connected to the container and        configured to operatively translate the one or more dies into a        predetermined relative position with respect to a 3D printing        bed; and/or    -   a 3D printing bed that operatively translates into a        predetermined relative position with respect to the one or more        dies;    -   wherein:        -   the rotor defines a rotational axis about which the rotor is            configured to operatively rotate;        -   a contained portion of the rotor is configured to            operatively remain within the container while operatively            translating along the rotational axis;        -   the first feedstock is fed through the stationary first            feedport while the contained portion is operatively            rotating;        -   the rotor defines a semi-contained portion located            immediately adjacent to the contained portion;        -   the rotor defines a contained perimeter located in a plane            that is oriented perpendicularly to the rotational axis and            that separates the contained portion from the semi-contained            portion;        -   the semi-contained portion operatively enters and exits the            container;        -   the machine operatively halts feeding the first feedstock            when the semi-contained portion begins entering the            container;        -   the contained perimeter is greater than a terminal perimeter            located at a non-driven terminal end of the rotor;        -   the rotor has a generally conical frustum shape;        -   while the contained portion is operatively rotating and/or            translating:            -   a magnitude of an axial gap continuously changes across                time, the axial gap measured along a first line                extending in a predetermined perpetual cross-sectional                plane that includes the rotational axis, the first line                extending parallel to the rotational axis, the gap being                the shortest distance, on the predetermined perpetual                cross-sectional plane and along the first line,                between (a) the exterior surface of the rotor and (b) a                second line that extends in the predetermined perpetual                cross-sectional plane, is perpendicular to the                rotational axis, and intersects a centroid of an exit of                the first feedport; and/or            -   a magnitude of a radial gap continuously changes across                time, the radial gap measured along the second line and                being the shortest distance, on the predetermined                perpetual cross-sectional plane and along the second                line, between the exterior of the rotor and the first                line;        -   as viewed along the rotational axis from the distal end, a            visible proximal perimeter of the rotor located proximal            from the distal end is greater than a visible distal            perimeter of the rotor located at the distal end; and/or        -   while the first feedstock is plastically deformed, a            microstructure of the first feedstock is changed.

Definitions

When the following phrases are used substantively herein, theaccompanying definitions apply. These phrases and definitions arepresented without prejudice, and, consistent with the application, theright to redefine these phrases via amendment during the prosecution ofthis application or any application claiming priority hereto isreserved. For the purpose of interpreting a claim of any patent thatclaims priority hereto, each definition in that patent functions as aclear and unambiguous disavowal of the subject matter outside of thatdefinition.

-   -   3D—three dimensional, that is, characterized by dimensions, such        as width, depth, and height, measured along each of three        mutually orthogonal axes.    -   3D print—to make parts and/or products using a computer-driven,        additive process, one layer at a time using plastic, metal, and        other materials directly from CAD drawings that have been cross        sectioned into thousands of layers.    -   a—at least one.    -   about—around and/or approximately.    -   above—at a higher level.    -   across—from one side, point, and/or moment to another.    -   activity—an action, act, step, and/or process or portion        thereof.    -   adapt—to design, make, set up, arrange, shape, configure, and/or        make suitable and/or fit for a specific purpose, function, use,        and/or situation.    -   adapter—a device used to effect operative compatibility between        different parts of one or more pieces of an apparatus or system.    -   adjacent—in close proximity to, near, next to, close, and/or        contiguous; adjoining; and/or neighboring.    -   after—following in time and/or subsequent to.    -   alloy— (v.) to unify, join, and/or form an amalgam and/or alloy;        (n.) a metallic solid and/or liquid that is composed of a        homogeneous mixture of two or more metals or of metals and        nonmetal and/or metalloid elements, usually for the purpose of        imparting and/or increasing specific characteristics and/or        properties; and/or a union, possessing metallic properties of        two or more metallic elements or of nonmetallic element (s) and        metallic elements(s) which are not pure compounds and which are        miscible with each other, which at least to a certain extent        when molten forms a more or less homogeneous liquid having a        metallic matrix and which does not separate into distinct layers        when solid. Such combinations when solidified from a melt may        consist of mechanical mixtures, entectics, entectoids, solid        solutions, or in part of chemical compounds one or more of which        may exist at the same time.    -   along—through, on, beside, over, in line with, and/or parallel        to the length and/or direction of; and/or from one end to the        other of.    -   an—at least one.    -   and—in conjunction with.    -   and/or—either in conjunction with or in alternative to.    -   annular—shaped like a ring.    -   any—one, some, every, and/or all without specification.    -   apparatus—an appliance or device for a particular purpose.    -   approximately—about and/or nearly the same as.    -   are—to exist.    -   around—about, surrounding, and/or on substantially all sides of;        and/or approximately.    -   as long as—if and/or since.    -   associate—to join, connect together, and/or relate.    -   at—in, on, and/or near.    -   at least—not less than, and possibly more than.    -   at least one—not less than one, and possibly more than one.    -   away—on a path directed from a predetermined location.    -   axial—located on, around, or in the direction of an axis.    -   axis—a straight line about which a body and/or geometric object        rotates and/or can be conceived to rotate and/or a center line        to which parts of a structure and/or body can be referred.    -   bed—a machine base on which a moving part carrying a tool and/or        workpiece slides.    -   begin—to start.    -   between—in a separating interval and/or intermediate to.    -   bond—to attach and/or fasten things together.    -   button—a volume of material attached to a surface by bonding        and/or fastener.    -   by—via and/or with the use and/or help of    -   can—is capable of, in at least some embodiments.    -   cause—to bring about, provoke, precipitate, produce, elicit, be        the reason for, result in, and/or effect.    -   cavity—a hollow area defined within an object and/or a        passageway between objects    -   centroid—the center of mass of an object of uniform density        and/or a geometric figure; and/or the point whose coordinates        are the mean values of the coordinates of the points of a        geometric figure and/or set.    -   ceramic—any of various hard, brittle, heat-resistant, and        corrosion-resistant materials made by shaping and then firing a        nonmetallic mineral, such as clay, at a high temperature, and/or        the nonmetallic mineral from which such materials can be formed,        such as, for example, silica, silicon carbide, alumina,        zirconium oxide, and/or fused silica, calcium sulfate,        luminescent optical ceramics, bio-ceramics, and/or plaster, etc.    -   change—(v.) to alter, modify, and/or cause to be different; (n.)        the act, process, and/or result of altering and/or modifying.    -   channel—(v) to cause to flow via a defined passage, conduit,        and/or groove adapted to convey one or more fluids. (n) a        passage, conduit, and/or groove adapted to convey one or more        fluids.    -   closer—physically nearer.    -   closest—physically nearest.    -   component—a distinct constituent element and/or part; and/or one        of a set of two or more vectors having a sum equal to a given        vector.    -   composite—made of diverse materials, each of which is        identifiable, at least in part, in the final product.    -   composition—a composition of matter and/or an aggregate,        mixture, reaction product, and/or result of combining two or        more substances.    -   composition of matter—a combination, reaction product, compound,        mixture, formulation, material, and/or composite formed by a        human and/or automation from two or more substances and/or        elements.    -   comprising—including but not limited to.    -   conceive—to imagine, conceptualize, form, and/or develop in the        mind.    -   configure—to design, arrange, set up, shape, and/or make        suitable and/or fit for a specific purpose, function, use,        and/or situation.    -   conical—of, relating to, or shaped like a cone.    -   connect—to join or fasten together.    -   consolidate—to form into a compact mass.    -   contact—to touch.    -   contain—to, at least partially retain, restrain, and/or hold        and/or keep within limits.    -   container—something that, at least partially, holds, carries,        and/or encloses one or more items for transport, storage, and/or        protection, etc.    -   containing—including but not limited to.    -   continuously—in a manner uninterrupted in time, sequence,        substance, and/or extent.    -   convert—to transform, adapt, and/or change.    -   cooperatively—in concert.    -   corresponding—related, associated, accompanying, similar in        purpose and/or position, conforming in every respect, and/or        equivalent and/or agreeing in amount, quantity, magnitude,        quality, and/or degree.    -   couplable—capable of being joined, connected, and/or linked        together.    -   coupling—linking in some fashion.    -   cross-section—a section formed by a plane cutting through an        object, usually at a right angle to an axis.    -   create—to make, form, produce, generate, bring into being,        and/or cause to exist.    -   cut—to penetrate with a sharp edge; to strike a narrow opening        in; to separate from a main body; detach; and/or to form by        penetrating.    -   cycle—an interval of time during which a characteristic, often        regularly repeated event, and/or sequence of events occurs.    -   cyclical—of, relating to, and/or characterized by cycles.    -   define—to establish the meaning, relationship, outline, form,        and/or structure of; and/or to precisely and/or distinctly        describe and/or specify.    -   deform—to alter a shape of something by pressure and/or stress.    -   deposit—to lay down, leave, and/or place.    -   derive—to receive, obtain, and/or produce from a source and/or        origin.    -   determine—to find out, obtain, calculate, decide, deduce,        ascertain, and/or come to a decision, typically by        investigation, reasoning, and/or calculation.    -   device—a machine, manufacture, and/or collection thereof.    -   die—a device that defines one or more holes through which        plastic, metal, and/or other ductile and/or flowable material is        extruded and/or drawn.    -   dimension—an extension in a given direction and/or a measurement        in length, width, or thickness.    -   direction—a spatial relation between something and a course        along which it points and/or moves; a distance independent        relationship between two points in space that specifies the        position of either with respect to the other; and/or a        relationship by which the alignment and/or orientation of any        position with respect to any other position is established.    -   distinct—discrete and/or readily distinguishable from all        others.    -   distribution—a spatial array.    -   divide—to separate and/or segregate.    -   does not—fails to perform in a predetermined manner.    -   driven—powered, operated, and/or controlled.    -   during—at some time in a time interval.    -   each—every one of a group considered individually.    -   edge—a border at which a surface terminates.    -   effect—to provoke, elicit, cause, bring into existence, to bring        about, and/or to produce as a result.    -   effective—sufficient to bring about, provoke, elicit, and/or        cause.    -   elongated—drawn out, made spatially longer, and/or having more        length than width.    -   embodiment—an implementation, manifestation, and/or concrete        representation.    -   end—an extremity and its vicinity of something that has length;        a terminus.    -   enter—to come and/or flow into.    -   equal—substantially the same as.    -   estimate— (n) a calculated value approximating an actual        value; (v) to calculate and/or determine approximately and/or        tentatively.    -   exemplary—serving as an example, instance, and/or illustration.    -   exit— (v) to leave and/or flow out of; (n) a passage, opening,        and/or way out.    -   extend—to reach spatially outward and/or to move out and/or away        from.    -   exterior—substantially non-interior; and/or a region that is        outside of a device and/or system.    -   extrude—to shape by forcing through a die.    -   feed—to introduce, deliver, and/or cause to flow toward and/or        into, such as to an operation.    -   feeder—a device that moves material to an operation.    -   feedstock—a raw material used in the manufacture of a product.    -   fill—to introduce a filling to a container during operation.    -   fin—a relatively thin projecting rib and/or ridge.    -   first—an initial element in a set.    -   flat—a flat surface and/or part.    -   flute—a elongated groove.    -   for—with a purpose of    -   form— (v) to produce, make, compose, construct, build, generate,        and/or create; (n) a phase, structure, and/or appearance.    -   frame—a structure adapted to support and/or contain something.    -   from—used to indicate a source, origin, and/or location thereof.    -   frustum—the part of a three-dimensional object, such as a cone        or pyramid (which can be substantially solid or hollow), located        between two parallel planes cutting the object, especially the        section between the base and a plane parallel to the base.    -   further—in addition.    -   gap—a space between objects.    -   generally—popularly; widely; usually; for the most part; without        reference to particular instances or details; and/or not        specifically.    -   generate—to create, produce, give rise to, and/or bring into        existence.    -   glass—an inorganic product: (a) the constituents of which        generally include a glass former (e.g., As2O3, B2O3 GeO2, P2O5,        SiO2, V2O5) that has an essential characteristic of creating        and/or maintaining, singly, or in a mixture, that type of        structural disorder characteristic of a glassy condition, other        oxides that approach glass forming properties (e.g., Al2O3, BeO,        PbO, Sb2O3 TiO2, ZnO and ZrO2), as well as oxides that are        practically devoid of glass forming tendencies (e.g., BaO, CaO,        K2O, Li2O, MgO, Na2O and SrO), however, pure and modified        silica, silicon and slag are also included; (b) formed by fusion        and cooled to a rigid condition generally without        crystallization; (c) having no definite melting point (whereby        the mass has the characteristic of passing through a plastic        state before reaching a liquid state when heated); (d) incapable        in the solid state of permanent deformation; and (e) that which        fractures when subject to deformation tension.    -   grain structure—arrangement of crystals and/or components.    -   greater—larger, higher, and/or more than.    -   halt—to stop, discontinue, and/or fully impede motion in a        predetermined and/or principle direction.    -   having—possessing, characterized by, comprising, and/or        including but not limited to.    -   immediately—with no object and/or space intervening.    -   impose—to bring about by authority and/or force.    -   including—including but not limited to.    -   incorporate—to cause to comprise.    -   initialize—to prepare something for use and/or some future        event.    -   inner—closer than another to the center and/or middle.    -   install—to connect, set in position, and/or prepare for use.    -   into—to a condition, state, or form of, and/or toward, in the        direction of, and/or to the inside of.    -   is—to exist in actuality.    -   less than—having a measurably smaller magnitude and/or degree as        compared to something else.    -   line—a straight one-dimensional geometrical element of infinite        length whose identity is determined by two points.    -   located—situated approximately in a particular spot and/or        position.    -   longitudinal—of and/or relating to a length; placed and/or        running lengthwise.    -   longitudinal axis—a straight line defined parallel to an        object's length and passing through a centroid of the object.    -   machine—a device and/or assembly adapted to perform at least one        task.    -   magnitude—a number assigned to a quantity so that it can be        compared with other quantities.    -   material—a substance and/or composition.    -   may—is allowed and/or permitted to, in at least some        embodiments.    -   measure—to determine, as a dimension, quantification, and/or        capacity, etc., by observation.    -   melt—to be changed from a solid to a liquid state, especially by        the application of heat.    -   metal—any of a category of electropositive elements that usually        have a shiny surface, are generally good conductors of heat and        electricity, and can be melted or fused, hammered into thin        sheets, or drawn into wires; an element that is not designated a        nonmetal, i.e., not H, B, C, Si, N, P, O, S, Se, Te, a halogen        (i.e., F, Cl, Br, I, At), or a noble gas (i.e., He, Ne, Ar, Kr,        Xe, Rn).    -   metallurgical—of or relating to the science that deals with        procedures used in extracting metals from their ores, purifying        and alloying metals, creating useful objects from metals, and        the study of metals and/or their properties in bulk and/or at        the atomic level.    -   method—one or more acts that are performed upon subject matter        to be transformed to a different state or thing and/or are tied        to a particular apparatus, said one or more acts not a        fundamental principal and not pre-empting all uses of a        fundamental principal.    -   microstructure—a structure on a microscopic scale, such as under        magnification of 50× or greater.    -   more—a quantifier meaning greater in size, amount, extent,        and/or degree.    -   no—an absence of and/or lacking any.    -   non-driven—not driven.    -   non-parallel—not parallel.    -   nub—a protuberance, knob, and/or projection.    -   occur—to take place.    -   one—being and/or amounting to a single unit, individual, and/or        entire thing, item, and/or object.    -   onto—on top of; to a position on; upon.    -   operable—practicable and/or fit, ready, and/or configured to be        put into its intended use and/or service.    -   operatively—in a manner able to function and/or to work.    -   or—a conjunction used to indicate alternatives, typically        appearing only before the last item in a group of alternative        items.    -   oscillate—to vibrate, swing back and forth with a steady,        uninterrupted rhythm, and/or vary between alternate extremes,        usually within a definable period of time.    -   other—a different and/or distinct entity and/or not the same as        already mentioned and/or implied.    -   outer—farther than another from the center and/or middle.    -   outside—beyond a range, boundary, and/or limit; and/or not        within.    -   particulate—minute separate particles that are handled as bulk        and not as individual pieces.    -   partition—to divide and/or separate into parts.    -   per—for each and/or by means of.    -   perform—to begin, take action, do, fulfill, accomplish, carry        out, and/or complete, such as in accordance with one or more        criterion.    -   perimeter—the outer limits or boundary of an area.    -   perpendicular—intersecting at or forming substantially right        angles.    -   perpetual—continuing, existing, and/or being so forever and/or        for an indefinitely long time.    -   phase—a distinct state of matter characterized by homogeneous        composition and properties and the possession of a clearly        defined boundary    -   pipe— A hollow cylinder or tube used to conduct a liquid, gas,        or finely divided solid.    -   plane—a substantially flat surface and/or a surface containing        all the straight lines that connect any arbitrarily-selected two        points on it.    -   plastically—characterized by the capability of, and/or fact of,        being shaped, reshaped, formed, and/or deformed.    -   plurality—the state of being plural and/or more than one.    -   point— (n.) a defined physical and/or logical location in at        least a two-dimensional system and/or an element in a        geometrically described set and/or a measurement or        representation of a measurement having a time coordinate and a        non-time coordinate. (v.) to aim and/or indicate a position        and/or direction of.    -   polymer—a chemical compound and/or mixture of compounds formed        by polymerization (a chemical reaction in which two or more        molecules (often called “monomers”) combine via covalent        chemical bonds to form larger molecules that contain repeating        structural units). Examples of polymers include ABS's,        polyacetates, polyacrylics, alkyds, epoxies,        fluorothermoplastics, liquid crystal polymers, nylons, styrene        acrylonitriles, polybutylene terephthalates, polycarbonates,        thermoplastic elastomers, polyketones, polypropylenes,        polyethylenes, polystyrenes, PVC's, polyesters, polyurethanes,        thermoplastic rubbers, and/or polyamides, etc.    -   port—an opening adapted for insertion and/or passage of a part        and/or material.    -   portion—a visually and/or physically distinguishable part,        component, section, percentage, ratio, and/or quantity that is        less than a larger whole.    -   position—(n) a place and/or location, often relative to a        reference point. (v) to place, locate, orient, and/or arrange.    -   pre-—a prefix that precedes an activity that has occurred        beforehand and/or in advance.    -   precipitate—to separate a solid from a solution.    -   predetermine—to determine, decide, and/or establish in advance.    -   prevent—to hinder, avert, and/or keep from occurring.    -   prior—before and/or preceding in time or order.    -   probability—a quantitative representation of a likelihood of an        occurrence.    -   produce—to create, manufacture, make, and/or generate via a        physical effort.    -   product—something produced by human and/or mechanical effort.    -   project—to calculate, estimate, or predict.    -   property—a real, tangible, and/or intangible property.    -   protrusion—something that projects from an object and/or a        surface.    -   provide—to furnish, supply, give, and/or make available.    -   pure—having a substantially homogeneous and/or uniform        composition, not mixed, and/or substantially free of foreign        substances.    -   radial—pertain to that (e.g., lines, bars, beams of light, etc.)        that radiates and/or emanates from and/or converges to a common        center and/or central point; arranged like the radii of a circle    -   range—a measure of an extent of a set of values and/or an amount        and/or extent of variation.    -   ratio—a relationship between two quantities expressed as a        quotient of one divided by the other.    -   ray—a straight line extending from a point (also called        half-line).    -   react—to cause (a substance or substances) to undergo a chemical        reaction.    -   receive—to get as a signal, take, acquire, and/or obtain.    -   reciprocating—to move back and forth alternately.    -   recommend—to suggest, praise, commend, and/or endorse.    -   reduce—to make and/or become lesser and/or smaller.    -   relative—considered with reference to and/or in comparison to        something else.    -   remain—to stay in substantially a same location, position,        and/or state.    -   remove—to eliminate, remove, and/or delete, and/or to move from        a place or position occupied.    -   repeat—to do again and/or perform again.    -   repeatedly—again and again; repetitively.    -   request—to express a desire for and/or ask for.    -   result—(n.) an outcome and/or consequence of a particular        action, operation, and/or course; (v.) to cause an outcome        and/or consequence of a particular action, operation, and/or        course.    -   rod—an elongated structure having a cross-sections taken        perpendicular to its longitudinal axis that are substantially        elliptical and/or circular shaped, substantially uniform, and/or        small in relation to its length.    -   rotate—to turn around an axis and/or center.    -   rotational—about and/or around an axis.    -   rotor—a rotating portion of a machine.    -   said—when used in a system or device claim, an article        indicating a subsequent claim term that has been previously        introduced.    -   seamless—not having and/or joined by a seam or seams and/or        smoothly continuous and/or uniform in quality.    -   second—an element of a set that follows a first element.    -   secondary—second in an ordering.    -   section—a representation of a solid object as it would appear if        cut by an intersecting plane, so that the internal structure is        displayed.    -   segregate—to separate and/or space apart.    -   select—to make a choice or selection from alternatives.    -   semi-contained—partially contained.    -   separate—(n) distinct and/or not touching; (v) to disunite,        space, set, or keep apart and/or to be positioned intermediate        to.    -   set—a related plurality.    -   severe plastic deformation—the imposition of an average plastic        shear strain in excess of 0.5 on feedstock under stress.    -   shape—(n.) a characteristic surface, outline, and/or contour of        an entity; (v) to apply a characteristic surface, outline,        and/or contour to an entity.    -   sheet—a broad, relatively thin, surface, layer, and/or covering        having two parallel surfaces both dimensions of which are large        in comparison with the third dimension.    -   slot—a channel, opening, and/or aperture having a longer length        than a width of the opening.    -   solid-state—a material that is neither liquid nor gaseous, but        instead of definite shape and/or form.    -   species—a class of individuals and/or objects grouped by virtue        of their common attributes and assigned a common name; a        division subordinate to a genus.    -   spiral—a path of a point in a plane moving around a central        point while, on average, receding from or approaching it. When        considering a spiral that generally recedes from the central        point, for a given rotation about the central point, the spiral        need not have a continuously increasing radius from the central        point, however, each successive turn will have an increasing        radius. Thus, a portion of a spiral can be linear and/or        curvilinear.    -   stationary—substantially fixed with respect to an object of        reference.    -   step—a ledge and/or offset.    -   stir—to move about actively and/or busily; to pass a material        through, usually in circular motions, so as to mix or cool the        material; and/or to use an implement to move or rearrange a        material.    -   store—to place, hold, and/or retain data, typically in a memory.    -   substantially—to a great extent and/or degree.    -   substrate—an underlying material, surface, and/or layer.    -   support—to bear the weight of, especially from below.    -   surface—the face, exterior, and/or outer boundary of an object        and/or a material layer constituting and/or resembling such a        boundary.    -   system—a collection of mechanisms, devices, machines, articles        of manufacture, processes, data, and/or instructions, the        collection designed to perform one or more specific functions.    -   terminal—of, at, relating to, and/or forming a limit, boundary,        extremity, and/or end.    -   that—used as the subject or object of a relative clause; a        pronoun used to indicate a thing as indicated, mentioned before,        present, and/or well known.    -   through—across, among, between, and/or in one side and out the        opposite and/or another side of    -   to—a preposition adapted for use for expressing purpose.    -   transform—to change in measurable: form, appearance, nature,        and/or character.    -   translate—to move in a non-rotational manner and/or along a        substantially linear path, which can include wobbling,        oscillating, vibrating, and/or reciprocating.    -   transmit—to send as a signal, provide, furnish, and/or supply.    -   treatment—an act, manner, or method of handling and/or dealing        with someone and/or something.    -   tube—a pipe, hollow cylinder, and/or hollow rodlike member        consisting of a wall shaped in the form of a simple closed curve        and extending axially, providing a conduit throughout its length        wherein the wall might vary along its axial length in transverse        dimensions and/or shape; and/or an elongate member having a        longitudinal axis and defining a longitudinal cross-section        resembling any closed shape such as, for example, a circle, a        non-circle such as an oval (which generally can include a shape        that is substantially in the form of an obround, ellipse,        limacon, cardioid, cartesian oval, and/or Cassini oval, etc.),        and/or a polygon such as a triangle, rectangle, square, hexagon,        the shape of the letter “D”, the shape of the letter “P”, etc.        Thus, a right circular cylinder is one form of a tube, an        elliptic cylinder is another form of a tube having an elliptical        longitudinal cross-section, and a generalized cylinder is yet        another form of a tube.    -   undergo—to experience and/or be subjected to.    -   uniform—relatively homogenous.    -   unmelted—not melted.    -   upon—immediately or very soon after; and/or on the occasion of.    -   use—to put into service.    -   varies—changes over time.    -   via—by way of, with, and/or utilizing.    -   view—to look at, observe, gaze upon, examine, inspect, watch,        study, and/or consider.    -   volume—a mass and/or a three-dimensional region that an object        and/or substance occupies.    -   wall—a partition, structure, and/or mass that serves to enclose,        divide, separate, segregate, define, and/or protect a volume.    -   weight—a force with which a body is attracted to Earth or        another celestial body, equal to the product of the object's        mass and the acceleration of gravity; and/or a factor and/or        value assigned to a number in a computation, such as in        determining an average, to make the number's effect on the        computation reflect its importance, significance, preference,        impact, etc.    -   when—at a time and/or during the time at which.    -   wherein—in regard to which; and; and/or in addition to.    -   which—a pronoun adapted to be used in clauses to represent a        specified antecedent.    -   wipe—to rub, pass over, spread, smear, dislocate, move, remove,        and/or urge away from.    -   wire—an electrically conductive metallic strand and/or rod,        wherein all the diameters of the cross-sectional area taken at        right angles to its length are of substantially the same        dimension, and the cross-sectional area is small enough to allow        substantial flexibility and/or resiliency and permit bending        and/or flexing without substantial metal flow. A wire can be        stranded, cored, coated, and/or covered.    -   with—accompanied by.    -   with regard to—about, regarding, relative to, and/or in relation        to.    -   with respect to—about, regarding, relative to, and/or in        relation to.    -   within—inside the limits of.    -   without—not accompanied by and/or lacking.    -   wobble—to move and/or rotate with an uneven and/or rocking        motion and/or unsteadily from side to side.    -   zone—a region and/or volume having at least one predetermined        boundary.

NOTE

Various substantially and specifically practical and useful exemplaryembodiments of the claimed subject matter are described herein,textually and/or graphically, including the best mode, if any, known tothe inventor(s), for implementing the claimed subject matter by personshaving ordinary skill in the art. References herein to “in oneembodiment”, “in an embodiment”, or the like do not necessarily refer tothe same embodiment.

Any of numerous possible variations (e.g., modifications, augmentations,embellishments, refinements, and/or enhancements, etc.), details (e.g.,species, aspects, nuances, and/or elaborations, etc.), and/orequivalents (e.g., substitutions, replacements, combinations, and/oralternatives, etc.) of one or more embodiments described herein mightbecome apparent upon reading this document to a person having ordinaryskill in the art, relying upon his/her expertise and/or knowledge of theentirety of the art and without exercising undue experimentation. Theinventor(s) expects any person having ordinary skill in the art, afterobtaining authorization from the inventor(s), to implement suchvariations, details, and/or equivalents as appropriate, and theinventor(s) therefore intends for the claimed subject matter to bepracticed other than as specifically described herein. Accordingly, aspermitted by law, the claimed subject matter includes and covers allvariations, details, and equivalents of that claimed subject matter.Moreover, as permitted by law, every combination of the herein describedcharacteristics, functions, activities, substances, and/or structuralelements, and all possible variations, details, and equivalents thereof,is encompassed by the claimed subject matter unless otherwise clearlyindicated herein, clearly and specifically disclaimed, or otherwiseclearly unsuitable, inoperable, or contradicted by context.

The use of any and all examples, or exemplary language (e.g., “such as”)provided herein, is intended merely to better illuminate one or moreembodiments and does not pose a limitation on the scope of any claimedsubject matter unless otherwise stated. No language herein should beconstrued as indicating any non-claimed subject matter as essential tothe practice of the claimed subject matter.

Thus, regardless of the content of any portion (e.g., title, field,background, summary, description, abstract, drawing figure, etc.) ofthis document, unless clearly specified to the contrary, such as viaexplicit definition, assertion, or argument, or clearly contradicted bycontext, with respect to any claim, whether of this document and/or anyclaim of any document claiming priority hereto, and whether originallypresented or otherwise:

-   -   there is no requirement for the inclusion of any particular        described characteristic, function, activity, substance, or        structural element, for any particular sequence of activities,        for any particular combination of substances, or for any        particular interrelationship of elements;    -   no described characteristic, function, activity, substance, or        structural element is “essential”; and    -   within, among, and between any described embodiments:        -   any two or more described substances can be mixed, combined,            reacted, separated, and/or segregated;        -   any described characteristic, function, activity, substance,            component, and/or structural element, or any combination            thereof, can be specifically included, duplicated, excluded,            combined, reordered, reconfigured, integrated, and/or            segregated;        -   any described interrelationship, sequence, and/or dependence            between any described characteristics, functions,            activities, substances, components, and/or structural            elements can be omitted, changed, varied, and/or reordered;        -   any described activity can be performed manually,            semi-automatically, and/or automatically;        -   any described activity can be repeated, performed by            multiple entities, and/or performed in multiple            jurisdictions.

The use of the terms “a”, “an”, “said”, “the”, and/or similar referentsin the context of describing various embodiments (especially in thecontext of the following claims) are to be construed to cover both thesingular and the plural, unless otherwise indicated herein or clearlycontradicted by context.

The terms “comprising,” “having,” “including,” and “containing” are tobe construed as open-ended terms (i.e., meaning “including, but notlimited to,”) unless otherwise noted.

When any number or range is described herein, unless clearly statedotherwise, that number or range is approximate. Recitation of ranges ofvalues herein are merely intended to serve as a shorthand method ofreferring individually to each separate value falling within the range,unless otherwise indicated herein, and each separate value and eachseparate sub-range defined by such separate values is incorporated intothe specification as if it were individually recited herein. Forexample, if a range of 1 to 10 is described, that range includes allvalues therebetween, such as for example, 1.1, 2.5, 3.335, 5, 6.179,8.9999, etc., and includes all sub-ranges therebetween, such as forexample, 1 to 3.65, 2.8 to 8.14, 1.93 to 9, etc., even if those specificvalues or specific sub-ranges are not explicitly stated.

When any phrase (i.e., one or more words) appearing in a claim isfollowed by a drawing element number, that drawing element number isexemplary and non-limiting on claim scope.

No claim or claim element of this document is intended to invoke 35 USC112(f) unless the precise phrase “means for” is followed by a gerund.

Any information in any material (e.g., a United States patent, UnitedStates patent application, book, article, web page, etc.) that has beenincorporated by reference herein, is incorporated by reference herein inits entirety to its fullest enabling extent permitted by law yet only tothe extent that no conflict exists between such information and theother definitions, statements, and/or drawings set forth herein. In theevent of such conflict, including a conflict that would render invalidany claim herein or seeking priority hereto, then any such conflictinginformation in such material is specifically not incorporated byreference herein. Any specific information in any portion of anymaterial that has been incorporated by reference herein that identifies,criticizes, or compares to any prior art is not incorporated byreference herein.

Applicant intends that each claim presented herein and at any pointduring the prosecution of this application, and in any application thatclaims priority hereto, defines a distinct patentable invention and thatthe scope of that invention must change commensurately if and as thescope of that claim changes during its prosecution. Thus, within thisdocument, and during prosecution of any patent application relatedhereto, any reference to any claimed subject matter is intended toreference the precise language of the then-pending claimed subjectmatter at that particular point in time only.

Accordingly, every portion (e.g., title, field, background, summary,description, abstract, drawing figure, etc.) of this document, otherthan the claims themselves and any provided definitions of the phrasesused therein, is to be regarded as illustrative in nature, and not asrestrictive. The scope of subject matter protected by any claim of anypatent that issues based on this document is defined and limited only bythe precise language of that claim (and all legal equivalents thereof)and any provided definition of any phrase used in that claim, asinformed by the context of this document when reasonably interpreted bya person having ordinary skill in the relevant art.

What is claimed is:
 1. A method for producing an extruded material fromone or more feedstocks, the method comprising performing the activitiesof: feeding a deformable solid-state first feedstock selected from theone or more feedstocks through a stationary first feedport and into acavity defined between a rotor and an inner wall of a stationarycontainer; upon contacting the first feedstock with the rotor, withoutmelting the first feedstock, creating a stirred material within thecavity via activities comprising plastically deforming the firstfeedstock; and continuously extruding the stirred material from thecavity through one or more dies to generate an extruded material;wherein: the rotor defines a rotational axis about which the rotor isconfigured to operatively rotate; the rotor defines a contained portionthat operatively remains within the container; the first feedstock isfed through the stationary first feedport while the contained portion ofthe rotor is operatively rotating; the contained portion has a generallyconical frustum shape that defines a proximal end and a distal end, theproximal end located closer to a driven portion of the rotor than thedistal end; while the contained portion is operatively rotating: amagnitude of an axial gap continuously changes across time, the axialgap measured along a first line extending in a predetermined perpetualcross-sectional plane that includes the rotational axis, the first lineextending parallel to the rotational axis, the gap being the shortestdistance, on the predetermined perpetual cross-sectional plane and alongthe first line, between (a) the exterior surface of the rotor and (b) asecond line that extends in the predetermined perpetual cross-sectionalplane, is perpendicular to the rotational axis, and intersects acentroid of an exit of the first feedport; and/or a magnitude of aradial gap continuously changes across time, the radial gap measuredalong the second line and being the shortest distance, on thepredetermined perpetual cross-sectional plane and along the second line,between the exterior of the rotor and the first line; as viewed alongthe rotational axis from the distal end, a visible proximal perimeter ofthe rotor located proximal from the distal end is greater than a visibledistal perimeter of the rotor located at the distal end.
 2. The methodof claim 1, further comprising: during the feeding of the firstfeedstock into the cavity, wiping a portion of the stirred material fromthe rotor.
 3. The method of claim 1, further comprising: during thefeeding of the first feedstock into the cavity, feeding a secondfeedstock selected from the one or more feedstocks through a stationarysecond feedport and into the cavity.
 4. The method of claim 1, furthercomprising: during the feeding of the first feedstock into the cavity,feeding a second feedstock selected from the one or more feedstocksthrough a stationary second feedport and into the cavity; andincorporating the second feedstock into the stirred material.
 5. Themethod of claim 1, further comprising: during the feeding of the firstfeedstock into the cavity, feeding a second feedstock selected from theone or more feedstocks through a stationary second feedport and into thecavity; dividing the second feedstock; and incorporating the secondfeedstock into the stirred material.
 6. The method of claim 1, furthercomprising: during the feeding of the first feedstock into the cavity,feeding a second feedstock selected from the one or more feedstocksthrough a stationary second feedport and into the cavity; and within thecavity, reacting the second feedstock with the first feedstock.
 7. Themethod of claim 1, further comprising: metallurgically and seamlesslybonding or consolidating the stirred material within the cavity.
 8. Themethod of claim 1, further comprising: causing the stirred material toundergo melting, segregation, partitioning, or precipitation.
 9. Themethod of claim 1, further comprising: depositing the extruded materialonto a substrate.
 10. The method of claim 1, further comprising: duringthe plastically deforming activity, alloying the first feedstock with asecond feedstock selected from the one or more feedstocks.
 11. Themethod of claim 1, wherein: said feeding activity occurs continuously.12. The method of claim 1, wherein: said feeding activity occurscyclically.
 13. The method of claim 1, wherein: said extruding activitycomprises back-extruding the extruded material through the rotor. 14.The method of claim 1, wherein: the rotor does not operatively effectthe activity of feeding the first feedstock when the contained portionoperatively translates along the rotational axis.
 15. The method ofclaim 1, wherein: the rotor is configured to operatively change thevolume of the cavity while the rotor is operatively translating alongthe rotational axis of the rotor.
 16. The method of claim 1, wherein:the rotor defines one or more fins, flutes, flats, slots, steps, steppedspirals, nubs, buttons, cutting edges, and/or protrusions.
 17. Themethod of claim 1, wherein: the inner wall of the container defines oneor more fins, flutes, flats, slots, steps, stepped spirals, nubs,buttons, cutting edges, and/or protrusions.
 18. The method of claim 1,wherein: the first feedstock enters the cavity in direction non-parallelto the rotational axis.
 19. The method of claim 1, wherein: the extrudedmaterial is extruded through the die in direction non-parallel to therotational axis.
 20. The method of claim 1, wherein: the rotor and thedie are configured to cooperatively impose an elongated form onto theextruded material, the elongated form having an annular shape.
 21. Themethod of claim 1, wherein: a composition of the extruded materialvaries along a longitudinal axis of the extruded material.
 22. Themethod of claim 1, wherein: at least one feedstock from the one or morefeedstocks is in the form of particulates, powder, granules, machinedchips, and/or swarfs.
 23. The method of claim 1, wherein: at least onefeedstock from the one or more feedstocks comprises a metal, alloy,ceramic, polymer, or glass.
 24. The method of claim 1, wherein: theextruded material has the form of a pipe or tube filled with a materialother than the extruded material.
 25. The method of claim 1, wherein:the extruded material comprises a pure metal, an alloy, and/or acomposite.
 26. The method of claim 1, wherein: the extruded material hasa microstructure defined by substantially uniform distribution of grainstructure and one or more secondary phases.
 27. A method for producingan extruded material from one or more feedstocks, the method comprisingperforming the activities of: feeding a deformable solid-state firstfeedstock selected from the one or more feedstocks through a stationaryfirst feedport and into a cavity defined between a rotor and an innerwall of a stationary container; upon contacting the first feedstock withthe rotor, without melting the first feedstock, creating a stirredmaterial within the cavity via activities comprising plasticallydeforming the first feedstock; and continuously extruding the stirredmaterial from the cavity through one or more dies to generate anextruded material; wherein: the rotor defines a rotational axis aboutwhich the rotor is configured to operatively rotate; a contained portionof the rotor is configured to operatively remain within the containerwhile operatively translating along the rotational axis; the firstfeedstock is fed through the stationary first feedport while thecontained portion is operatively rotating; the rotor defines asemi-contained portion located immediately adjacent to the containedportion; the rotor defines a contained perimeter located in a plane thatis oriented perpendicularly to the rotational axis and that separatesthe contained portion from the semi-contained portion; thesemi-contained portion operatively enters and exits the container; thefeeding activity is operatively halted when the semi-contained portionbegins entering the container; the contained portion has a generallyconical frustum shape that defines a proximal end and a distal end, theproximal end located closer to a driven portion of the rotor than thedistal end; while the contained portion is operatively rotating andtranslating: a magnitude of an axial gap continuously changes acrosstime, the axial gap measured along a first line extending in apredetermined perpetual cross-sectional plane that includes therotational axis, the first line extending parallel to the rotationalaxis, the gap being the shortest distance, on the predeterminedperpetual cross-sectional plane and along the first line, between (a)the exterior surface of the rotor and (b) a second line that extends inthe predetermined perpetual cross-sectional plane, is perpendicular tothe rotational axis, and intersects a centroid of an exit of the firstfeedport; and/or a magnitude of a radial gap continuously changes acrosstime, the radial gap measured along the second line and being theshortest distance, on the predetermined perpetual cross-sectional planeand along the second line, between the exterior of the rotor and thefirst line; as viewed along the rotational axis from the distal end, avisible proximal perimeter of the rotor located proximal from the distalend is greater than a visible distal perimeter of the rotor located atthe distal end.
 28. A machine configured for producing an extrudedmaterial from one or more feedstocks, the machine comprising: afeedstock feeder that operatively feeds a deformable solid-state firstfeedstock selected from the one or more feedstocks through a stationaryfirst feedport and into a cavity defined between a rotating rotor and aninner wall of a stationary container; and a rotor that, upon contactingthe first feedstock with the rotating rotor and without melting thefirst feedstock, operatively creates an unmelted stirred material withinthe cavity via activities comprising plastically deforming the firstfeedstock; wherein: the rotor defines a rotational axis about which therotor is configured to operatively rotate; a contained portion of therotor is configured to operatively remain within the container whileoperatively translating along the rotational axis; the first feedstockis fed through the stationary first feedport while the contained portionis operatively rotating; the rotor defines a semi-contained portionlocated immediately adjacent to the contained portion; the rotor definesa contained perimeter located in a plane that is orientedperpendicularly to the rotational axis and that separates the containedportion from the semi-contained portion; the semi-contained portionoperatively enters and exits the container; the machine operativelyhalts feeding the first feedstock when the semi-contained portion beginsentering the container; the contained perimeter is greater than aterminal perimeter located at a non-driven terminal end of the rotor;the rotor has a generally conical frustum shape; while the containedportion is operatively rotating and/or translating: a magnitude of anaxial gap continuously changes across time, the axial gap measured alonga first line extending in a predetermined perpetual cross-sectionalplane that includes the rotational axis, the first line extendingparallel to the rotational axis, the gap being the shortest distance, onthe predetermined perpetual cross-sectional plane and along the firstline, between (a) the exterior surface of the rotor and (b) a secondline that extends in the predetermined perpetual cross-sectional plane,is perpendicular to the rotational axis, and intersects a centroid of anexit of the first feedport; and/or a magnitude of a radial gapcontinuously changes across time, the radial gap measured along thesecond line and being the shortest distance, on the predeterminedperpetual cross-sectional plane and along the second line, between theexterior of the rotor and the first line; as viewed along the rotationalaxis from the distal end, a visible proximal perimeter of the rotorlocated proximal from the distal end is greater than a visible distalperimeter of the rotor located at the distal end; and while the firstfeedstock is plastically deformed, a microstructure of the firstfeedstock is changed.
 29. The machine of claim 1, further comprising: atranslatable feeder frame connected to the container and configured tooperatively feed a predetermined quantity of one or more of feedstocksthrough the feedport and into the cavity.
 30. The machine of claim 1,further comprising: a 3D printing bed that operatively translates into apredetermined relative position with respect to the one or more dies.